Manual Name

Pub. No.

(USA and CANADA)

SUPRA Repair Manual

Supra Electrical Wiring Diagram
Manual

1/2 SUPRA New Car Features
(Models except USA and CANADA)

SUPRA Chassis and Body Repair Manual

Supra Electrical Wiring Diagram
Manual

SUPRA New Car Features
(All Countries)

Fundamental Painting Procedures

Fundamental Body Repair Procedures

BRM024E
BRM002E

NCF097E

RM344E
EWD175Y

NCF096U

M/Y Version
M/Y Version

FOREWORD

This repair manual has been prepared to provide information on
the repair methods (including cutting and welding operations, but
excluding painting) for collision-damaged body components of the
TOYOTA SUPRA.

Applicable models: JZA80 series

This manual consists of body repair methods, exploded diagrams
and illustrations of the body components and other information re-
lating to body panel replacement such as handling precautions,
etc. However, it should be noted that the front fenders of the
TOYOTA models are bolted on and require no welding.

Body construction will sometimes differ depending on specifica-
tions and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for gen-
eral destinations.

For the repair procedures and specifications other than collisionda-
maged body components of the TOYOTA SUPRA refer to the fol-
lowing repair manuals.

If you require the above manuals, please contact your TOYOTA
Dealer.

All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures are
subject to change without prior notice.

TOYOTA MOTOR CORPORATION

in.

100
200

3.94
7.87

QUARTER PANEL (CUT)

(Cut and Join Location)
Normal Roof

BODY PANEL. REPLACEMENT

RE-34

HOW TO USE THIS MANUAL

Each repair method description provided in Section RE of this manual comprises two pages, divided into
2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair.

REMOVAL

(Cut and Join Location)

200 mm

Cut and Join Location

100 mm

Cut and Join
Location

(Cut and Join Location)
Sport Roof

Cut and Join Location
(Cut Location for Supply Parts)

Cut and join the parts at the location shown above.

REPLACEMENT PARTS AND METHOD

(CUT)

QUARTER PANEL

Replacement method

(ASSY)

Assembly replacement

. . . . .

(CUT)

Major cutting (less than 1/2 of parts used)

. . . . . .

(CUT-H)

Half cutting (about 1/2 of parts used)

. . . .

(CUT-P)

Partial cutting (most of parts used)

. . . .

Replacement parts

PARTS LOCATION

REMOVAL DIAGRAM

Describes in detail removal of the damaged parts involving repair by cutting.

REMOVAL GUIDE

Provides additional information to more efficiently help you perform the removal.

INTRODUCTION

IN-2

in.

0.20

Normal Roof:

Sport Roof:

Before temporarily installing the new parts, apply
body sealer to the wheel arch.

HINT:
1)

Apply body sealer about 5 mm (0.20 in.) from the
flange, avoiding any oozing.

Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16
in.) in diameter.

For other sealing points, refer to section AR.

BODY PANEL REPLACEMENT

RE-36

INSTALLATION

Butt Weld

Body Sealer

Butt Weld

Body Sealer

about 5 mm

Temporarily install the new parts and check the fit of
the front door, back door and rear combination lamp.

Apply foamed material to the pillar section.

HINT: For the foamed material application areas, refer to
page AP-4.

INSTALLATION DIAGRAM

Describes in detail installation of the new parts involving repair by welding and/or cutting, but
excluding painting.

INSTALLATION GUIDE

Provides additional information to more efficiently help you perform the installation.

SYMBOLS

See page

IN-4

ILLUSTRATION OF WELD POINTS

Weld method and panel position symbols.
See page

IN-5

INTRODUCTION

IN-3

SYMBOLS

MEANING

ILLUSTRATION

SAW CUT OR
ROUGH CUT

REMOVE BRAZE

(See page

IN-5

)

SPOT WELD OR
MIG PLUG WELD

WELD POINTS

BRAZE

CONTINUOUS MIG
WELD (BUTT WELD
OR TACK WELD)

BODY SEALER

SYMBOLS

The following symbols are used in the welding Diagrams in Section RE of this manual to indicate cutting
areas and the types of weld required.

INTRODUCTION

IN-4

Remove weld point and panel position

Weld points

REMOVAL

Weld method and panel position

Weld points

INSTALLATION

SYMBOL

MEANING

ILLUSTRATION

SYMBOL

Spot Weld

MEANING

ILLUSTRATION

Remove
Weld
Points

(Outside)

Mig Plug
Weld

(Middle)

(Inside)

Spot MIG
Weld

HINT: Panel position syrnbols are as seen from the
working posture.

Illustration of Weld Point Symbols

EXAMPLE:

INTRODUCTION

IN-5

Steering Wheel Pad
(with Airbag)

Junction Block No. 1

Center Airbag Sensor Assembly

Front Airbag Sensor LH

Front Passenger Airbag Assembly

Front Airbag Sensor RH

SRS Warning Light

Spiral Cable

Locations of SRS Components

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Servicing vehicle with a Supplemental Restraint System (referrerd to as the SRS in the remainder of this
manual) installed.
When handling SRS components (removal, installation or inspection, etc.), always follow the directions
given in the repair manual for the relevant model year to prevent the occurrence of accidents and airbag
malfunction.
Also take the following precautions when repairing the body:

Work must be started after 90 seconds or longer from the time the ignition switch is set to the LOCK
position and the negative (-) terminal cable is disconnected from the battery.
(The airbag system is equipped with a backup power source so that if work is started within 20 seconds
of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat, outside rear view mirror and power shoul-
der belt anchorage, which are all equipped with memory function, it is not possible to make a record of
the memory contents. So when the operation is finished, it will be necessary to explain this fact to the
customer, and request the customer to adjust the features and reset the memory.

When using electric welding, first disconnect the SRS connector (yellow color and 2 pins) under the
steering column near the combination switch connector on the glove compartment finish plate and lower
the front scuff plate before starting work.

INTRODUCTION

IN-6

Front Fender Area

Before repairing the body, remove the SRS parts if, during repair, shocks are likely to be applied to
the sensors due to vibrations of the body or direct tapping with tools or other parts.

Do not expose the SRS parts directly to hot air or flames.
NOTICE:
1)

The maximum ambient temperature tolerance is 120

C (248

F) for the front airbag sensor,

105

C (221

F) for the center airbag sensor assembly and 93

C (200

F) for the steering wheel

pad, and front passenger airbag assembly. If it is possible that the ambient temperature may
reach or exceed the temperature limit, remove the sensors and the steering wheel pad from
the vihicle or protect them with a hot insulation material before starting work.

Prior to welding, remove adjacent SRS parts from the vehicle or protect there with fire-proof
covers.

If the front fender or periphery of the vehicle is damaged, visually inspect for damage to the front
airbag sensor using the inspection procedures described in section RS of the repair manual for the
relevant model year.
Also check that the dimensions of the body where the front airbag sensor is installed match those
in the body dimension drawings.
(The airbag may malfunction, or may not work, if the mounting angle or dimensions of the sensor
mount are not correct.)

If the vehicle is damaged, visually inspect for damage to the steering wheel pad using the inspection
procedures described in section RS of the repair manual for the relevant model year.

When removing or handling the steering wheel pad, and front passenger airbag assembly keep the
pad upper surface facing upward. Also, lock the lock lever of the twin lock type connector at the rear
of the pad and take care not to damage the connector.
(Storing the pad or front passenger airbag assembly with its metalic surface up may lead to a serious
accident if the airbag inflates for some reason.)

Store the steering wheel pad and the front passenger airbag assembly where the ambient tempera-
ture remains below 93

C (200

F), without high humidity and away from electrical noise.

Be careful not to let painting materials contact the SRS parts.

Information labels are attached to the periphery of the SRS components. Follow the NOTICES.

Store the airbag assembly where the ambient temperature remains below 93

C (200

F), without high

humidity and away from electrical noise.

INTRODUCTION

IN-7

Shift Lock ECU

Engine Control
Module
(Engine ECU)

Center Airbag
Sensor Assembly

ABS
Deceleration
Sensor

ABS and Traction ECU
(for 2JZ-GTE)

Stereo Power
Amplifier

Integration
Relay

J/B No. 1

Traction ECU
(for 2JZ-GTE)

R/B No. 4

Daytime Running
Light Relay (Main)
(for Canada)

Blower Control
Relay

PPS ECU

A/C Amplifier

Theft Deterrent
ECU

Cruise Control ECU

Auto Antenna Control Relay

ABS ECU

(for 2JZ-GE)

Component to be aligned

Section of repair manual

for relevant model year

Front Wheels

Suspension and Axle (SA) section

Rear Wheels

Suspension and Axle (SA) section

Propeller Shaft

Propeller Shaft (PR) section

3. DRIVE TRAIN AND CHASSIS

2. BRAKE SYSTEM

The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC
system.

The drive train and chassis are components-that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model year during alignment and section DI of this manual.

4. ECU (ELECTRONIC CONTROL UNIT)

Locations of ECUs

INTRODUCTION

IN-8

Light Failure Sensor

Fuel Pump ECU

Rear Wiper Relay

5. COMPONENTS ADJACENT TO THE BODY PANELS

Locations of ECUs (Cont’d)

Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80

C (176

F).

NOTICE: if it is possible the ambient temperature may reach 80

C (176

F) or more, remove the ECUs

from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.

Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the
components.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components an the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body
to ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.

INTRODUCTION

IN-9

GENERAL REPAIR INSTRUCTIONS

Work Precautions

VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats an carpet with heat-
resistant, fire-proof covers.

SAFETY
1.

Before performing repair work, check
for fuel leaks. If a leak is found, be
sure to close the opening totally.

If it is necessary to use a frame in the
area of the-fuel tank, first remove the
tank and plug the fuel line.

SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.

WRONG

Glass Cover

Safety Cable

Seat Cover

WRONG

HAND TOOLS
keeping your hand tools
in neat order improve
your work efficiency.

SAFETY WORK CLOTHES

In addition to the usual mechanic’s wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.

Dust-
Prevention
Mask.

Welder’s
Glasses

Ear
Plugs

Body
Mechanic
Stand

Face
Protector

Head
Protector

Eye
Protector

Welder’s
Gloves

Safety
Shoes

INTRODUCTION

IN-10

Proper and Efficient Work Procedures

REMOVAL

NUMBER OF SPOT WELDS AND PANEL POSITIONS
The number of spot welds and the panel positions to be
removed are shown for your reference.
HINT: See ”Symbols” on page

IN-4

PRE-REMOV AL MEASURING
Before removal or cutting
operations, take measurements
in accordance with the dimension
diagram. Always use a puller to
straighten a damaged body or
frame.

REMOVAL OF ADJACENT COMPONENTS
When removing adjacent components, apply
protective tape to the surrounding body and
your tools to prevent damage.
HINT: See ”Handling Precautions on Related
Components” on age

IN-6

PRECAUTIONS FOR DRILLING OR
CUTTING
Check behind any area to be drilled or
cut to insure that there are no hoses,
wires, etc., that may be damaged.
HINT: See ”Handling Precautions on
Related Components” on page

IN-6

CUTTING AREA
Always cut in a straight
line and avoid reinforced
area.

Cutting Okay

Corners

Reinforcement

WRONG

INTRODUCTION

IN-11

Thickness of

welded portion

Size of plug hole

1.0 (0.04) under

5 (0.20)

over

1.0 (0.04) - 1.5 (0.06)

6.5 (0.26)

over

1.5 (0.06) over

8 (0.31)

over

REFERENCE:

mm (in.)

PREPARATION FOR INSTALLATION

APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)

SPOT WELD POINTS

When welding panels with a
combined thickness of over
3 mm (0.12 in.), use a MIG
(Metal Inert Gas) welder for
plug welding.
HINT: spot welding will not
provide sufficient durability
for panels over 3 mm (0.12
in.) thick.

Remove the paint
from the portion of the
new parts and body to
be welded, and apply
weld-through primer.
HINT: See ”ANTI-
RUST TREATMENT”
on page

AR-2

Less than
3 mm

Air Saw

WRONG

Puncher

20 - 30 mm

Overlap

ROUGH CUTTING OF JOINTS
For joint areas, rough cut the
new parts, leaving 20 - 30 mm
(0.79 - 1.18 in.) overlap.

MAKING HOLES FOR PLUG WELDING
For areas where a spot welder cannot be
used, use a puncher or drill to make holes
for plug welding.

INTRODUCTION

IN-12

SPOT WELD LOCATIONS
Try to avoid welding over pre-
vious spots.

New Spot
Locations

WELDING PRECAUTIONS
1.

The number of welding
spots should be as follows.
Spot weld: 1.3 x No. of
manufacturer’s spots.
Plug weld: More than No.
of manufacturer’s plugs.

INSTALLATION

POST-WELDLNG REFINISH-
ING
1.

Always check the welded
spots to insure they are
secure.

When smoothing out the
weld spots with a disc
grinder, be careful not to
grind off too much as this-
would weaken the weld.

PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.

WRONG

OKAY

Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panels at areas other
than specified.

Safety Glass

Body
Measurement
Diagrams

SPOT WELDING PRECAUTIONS
1.

The shape of the welding tip
point has an effect on the
strength of the weld.

Always insure that the seams
and welding tip are free of
paint.

Oil
spot
Locations

Tip Cutter

INTRODUCTION

IN-13

Cartridge Type

ANTI-RUST TREATMENT

When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the
requirements of your country.
HINT: For further details, see the description given in section AR of this manual.

BODY SEALER
Apply body sealer to the
required areas.

ANTI-RUST AGENT (WAX)

Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.

Tube Type

UNDERCOAT
Apply undercoat to the underbody and
wheel housings.

spray Gun

Undercoating
(Oil base)

Undercoating
(Water base)

INTRODUCTION

IN-14

SUPPORT POSITION

PANTOGRAPH JACK POSITION

CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.

Front

Front crossmember

. . . . . . . .

Rear

Rear axle beam

. . . . . . . . .

JACK POSITION

Front

Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE LIFT AND SUPPORT LOCATIONS

INTRODUCTION

IN-15

ABS

Antilock Brake System

A/C Air

Conditioner

assy assembly

ECT

Electronic Controlled Transmission

ECU

Electronic Control Unit

e.g.

Exempli Gratia (for Example)

Ex. Except

FWD

Front Wheel Drive Vehicles

4WD

Four Wheel Drive Vehicles

in. inch

LH Left-hand

LHD Left-hand

Drive

MIG

Metal Inert Gas

M/Y Model

Year

PPS

Progressive Power Steering

RH Right-hand

RHD Right-hand

Drive

SRS

Supplemental Restraint System

w/ with

w/o without

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this
manual.

INTRODUCTION

IN-16

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

ANTI–CORROSION TREATMENT

PAGE 1 of 4

SECTION:

GENERAL INFORMATION BULLETIN #82

MODELS:

ALL

DATE:

DECEMBER 1997

To prevent corrosion and reduce interior noise when replacing body panels, always apply
corrosion inhibiting and sound dampening materials such as body sealer, cavity wax,
undercoating and body foam according to Toyota recommendations.

These recommendations can be found in the Anti–Rust Treatment (AR) section of the
model specific Repair Manual for Collision Damage publication. Collision repair manuals
can be obtained through a Toyota dealership parts department.

BODY SEALER

For waterproofing and corrosion protection measures, always apply body sealer to the
seams and hems of the doors, hoods, etc.

Apply body sealer to required areas:

Door seams (Illustration A.)

Underhood seams (Illustration B.)

Wherever body sealer has been removed during a repair

Illustration A.

Illustration B.

ANTI–CORROSION TREATMENT (cont’d)

PAGE 2 of 4

CAVITY WAX

To provide corrosion resistance, always apply cavity wax to the inside of the hemming
areas of the doors and hoods, around the hinges, and to the welded surfaces inside the
boxed cross–section structure of the side member, body pillar, etc.

Apply cavity wax to required areas:

Inside of the hems of the doors and hoods (Illustration A.)

Around the hinges of the doors and hood (Illustration B.)

Wherever the original cavity wax was disturbed during a repair

Illustration A.

Illustration B.

UNDERCOATING

To protect the body from damage by flying stones, always apply chip resistant materials to
the bottom surfaces of the underbody and inside of the wheel housing.

Apply chip resistant materials to all welded areas and panel joints (Illustration A.); then
apply to the entire area (Illustration B.).

Illustration A.

Illustration B.

ANTI–CORROSION TREATMENT (cont’d)

PAGE 3 of 4

BODY FOAM

Apply body foam to all areas where foam was damaged or removed during a repair. This
will restore sound deadening characteristics and corrosion protection.

Apply body foam to all required areas:

“A”, “B” and “C” pillar

Rocker panels

Wherever foam was disturbed or removed during a repair

The information on the application of all anti–corrosion materials is contained in the
Anti–Corrosion Treatment section (AR), and throughout the Body Panel Replacement
section of the Toyota Repair Manual for Collision Damage Publications. Information on
anti–corrosion material application can also be found in the Fundamental Body Repair
Procedures manual and the Noise, Vibration, and Harshness manual.

These publications may be obtained through your local Toyota dealership parts department
or by obtaining the part number and calling:

1–800–622–2033

Mon–Fri

7:00 a.m. to 4:30 p.m. Pacific Standard Time

This information can also be obtained by attending Toyota Collision Repair and Refinish
training courses:

Non–Structural Body Repair Techniques

Structural Body Repair Techniques

ANTI–CORROSION TREATMENT (cont’d)

PAGE 4 of 4

MANUFACTURERS LIST

Provided is a list of manufacturers. Call them directly to obtain a list of their products or a
product demonstration brochure.

Phone

Web site

3M:

1–800–877–9344

N/A

Kent:

1–800–654–6333

http://www.farnell.co.uk

Dominion:

1–800–265–0790

http://www.dominionsureseal.com

SEM:

1–800–831–1122

N/A

Crest:

1–800–822–1400

http://www.crestauto.com

Wurth:

Western area

1–800–346–4198

http://www.wurthwest.com

Illinois

1–800–99–WURTH

http://www.wurthillinois.com

Florida

1–800–829–8316

http://www.wurthflorida.com

All other states

1–800–526–5228

http://www.wurthusa.com

mm (in.)

NO8903
NO8971

HINT: For symbols, capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (Seen from rear).

1,617
(63.66)

263
(10.35)

652
(25.67)

A-L, a-l

C-l, c-L

G-g

Vehicle Dimensions

(Three-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Front fender apron standard hole

10 (0.39)

J, j

Front side member reinforcement standard hole

8 (0.31)

B, b

Front spring support hole-front

11 (0.43)

Cooling fan installation nut

6 (0.24) nut

C, c

Cowl top side panel standard hole

10 (0.39)

L, l

Front fender installation nut

6 (0.24) nut

Cowl top panel center mark

M, m

Hood hinge installation nut

8 (0.31) nut

E, e

Front side member working hole

18 (0.71)

N, n

Headlight installation nut

6 (0.24) nut

F, f

Front side member standard hole

13 (0.51)

O, o

Headlight installation hole

14x10.6
(0.55x0.42)

G, g

Radiator duct installation hole

7.2 (0.283)

P, p

Headlight installation hole

H, h

Radiator support apron brace standard hole

10 (0.39)

Q, q

Headlight installation hole

I, i

Apron fender side extension standard hole

9 (0.35)

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT

14x9
(0.55x0.35)
14x9
(0.55x0.35)

BODY DIMENSIONS

DI-3

BODY LOWER BACK PANEL (ASSY)

REMOVAL

Braze

BODY PANEL REPLACEMENT

RE-48

INSTALLATION

Braze

Temporarily installing the new parts, check the
fit of the back door and rear combination lamp.

BODY PANEL REPLACEMENT

RE-49

NO8905

1,148
(45.20)

J-j

E-e

1,095
(43.11)

1,488
(58.58)

F-f

K-k

1,081
(42.56)

G-g

1,260
(49.61)

L-1

Vehicle Dimensions Left

↔

Right

1,506
(59.29)

1,510
(59.45)

M-m

H-h

1,530
(60.24)

1,510
(59.45)

I-i

1,545
(60.83)

G-m
or
g-M

E-g
or
e-G

1,871
(73.66)

1,602
(63.07)

1,548
(60.94)

E-h
or
e-H

H-i
or
h-I

1,538
(60.56)

I-l
or
i-L

E-i
or
e-I

1,566
(61.65)

E-l
or
e-L

J-k
or
j-K

1,227
(48.31)

1,333
(52.48)

L-m
or
l-M

G-l
or
g-L

1,.465
(57.68)

1,846
(72.68)

HINT: For symbols, capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (Seen from rear).

J-k
or
j-K

568
(22.36)

mm(in.)

(Three-Dimensional

Distance)

Hole dia.

7.3 (0.29)

Name

Rocker panel reinforcement adjoining portion mark
Rocker panel reinforcement adjoining portion mark

Weatherstrip installation hole

Weatherstrip installation hole
Quater panel adjoining portion mark
Quater panel adjoining portion mark

Symbol

H, h

I, i

J, j

K, k

L, l

M, m

Hole dia.

10 (0.39)nut

Name

Roof panel/ Front body pillar adjoining portion

Cowl top panel/ Front body pillar adjoining portion

Front door hinge installation nut

Front door hinge installation nut
Front body pillar adjoining portion mark

Front body pillar adjoining portion mark
Front body pillar adjoining portion mark

Symbol

A, a

B, b

C, c

D, d

E, e

F, f

G, g

BODY

OPENING AREAS

(Side V

iew: Sport Roof)

BODY

DIMENSIONS

DI-5

NO8906

HINT: For symbols, capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (Seen from rear).

(Three-Dimensional

Distance)

mm (in.)

Hole dia.

10 (0.39)

Name

Back door opening trough / Quater panel adjoining portion

Lower back panel reinforcement standard hole

Roof side rail adjoining portion mark

Symbol

D, d

E, e

F, f

Hole dia.

8 (0.31)

9 (0.35)

Name

Back door opening frame center mark

Damper stay installation hole-rear
Rear spring support hole-inner, front

Symbol

B, b

C, c

BODY

OPENING AREAS

(Rear V

iew: Normal Roof)

BODY

DIMENSIONS

DI-6

HINT: For symbols, capital letters indicate
right side of vehicle, small letters indicate
left side of vehicle (Seen from rear).

(Three-Dimensional

Distance)

mm (in.)

Hole dia.

10 (0.39)

Name

Back door opening trough / Quarter panel adjoining portion

Lower back panel reinforcement standard hole
Front body pillar adjoining portion mark

Symbol

D, d

E, e

F, f

Hole dia.

8 (0.31)

9 (0.35)

Name

Back door opening frame center mark

Damper stay installation hole-rear
Rear spring support hole-inner, front

Symbol

B, b

C, c

BODY

OPENING AREAS

(Rear V

iew: Sport Roof)

BODY

DIMENSIONS

DI-7

NO8904

J-j

1,234
(48.58)

E-e

1,094
(43.07)

1,488
(58.58)

K-k

F-f

1,090
(42.91)

Vehicle Dimensions Left

↔

Right

G-g

1,260
(49.61)

L-l

1,506
(59.29)

1,530
(60.24)

H-h

M-m

1,510
(59.45)

I-i

1,531
(60.28)

G-m
or
g-M

E-g
or
e-G

1,871
(73.66)

1,602
(63.07)

E-h
or
e-H

H-i
or
h-I

1,546
(60.87)

1,530
(60.24)

I-k
or
i-K

E-i
or
e-I

1,573
(61.93)

1,418
(55.83)

1,566
(61.65)

E-l
or
e-L

I-l
or
i-L

1,846
(72.68)

G-l
or
g-L

L-m
or
l-M

1,465
(57.68)

HINT: For symbols, capital letters indi-
cate right side of vehicle, small letters
indicate left side of vehicle (Seen from
rear).

(Three-Dimensional

Distance)

mm (in. )

Hole dia.

Name

Rocker panel reinforcement adjoining portion mark

Rocker panel reinforcement adjoining portion mark
Roof side rail adjoining portion mark
Roof side rail adjoining portion mark

Quarter panel adjoining portion mark

Symbol

H, h

I, i

J, j

K, k

L, l

M, m

Hole dia.

10 (0.39)nut
10 (0.39)nut

Name

Roof panel/ Front body pillar adjoining portion

Cowl top panel/ Front body pillar adjoining portion
Front door hinge installation nut
Front door hinge installation nut

Front body pillar adjoining portion mark

Symbol

A, a

B, b

C, c

D, d

E, e

F, f

G, g

BODY

OPENING AREAS

(Side V

iew: Normal Roof)

BODY

DIMENSIONS

DI-4

BODY PANEL UNDERCOATING AREAS

HINT:
1.

First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover.

Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other
areas are accidently coated, wipe off the coating immediately.

Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat
over the entire area.

Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller
shaft.

Besides the locations described below, apply undercoating to all weld points under the body to
insure corrosion prevention.

Be sure to seal the edge of the flange of the member and bracket with undercoating.

If undercoat is damaged by peeling, cracks etc., be sure to repair as necessary.

REFERENCE: Referring to the notes above, undercoating should be applied according to the specifica-
tions for your country.

ANTI-RUST TREATMENT

AR-8

BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS

HINT:
1.

Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges.

Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the
part.

Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if
accidently applied to other areas.

Back Door Hinge

Hood Hinge

Back Door

Front Door

Door Hinge

ANTI-RUST TREATMENT

AR-9

BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS

HINT:
1.

Anti-chipping paint should be applied to some areas before the second coat and to others after the
top coat.

If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in a grease,
wax and silicone remover.

Soft-Chip Primer (body front)

PVC Chipping Primer (outside rocker panel)

Chipping Protector (plastic)

ANTI-RUST TREATMENT

AR-10

BODY PANEL SEALING AREAS

HINT:
1.

Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone
remover.

If weld through primer was used, first wipe off any excess and coat with anti-corrosion primer
before applying body sealer.

Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover.

If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary.

Flat Surfacing

ANTI-RUST TREATMENT

AR-4

Flat Surfacing

Sport Roof

Normal Roof

Flat Surfacing

Flat
Surfacing

Flat Surfacing

A/T only
Flat Surfacing

A/T only Flat Surfacing

ANTI-RUST TREATMENT

AR-5

Flat Surfacing

Normal Roof

Flat Surfacing

Sport Roof

Flat Surfacing

ANTI-RUST TREATMENT

AR-6

Flat Surfacing

All Around
Flat Surfacing

Flat Surfacing

ANTI-RUST TREATMENT

AR-7

COWL TOP SIDE PANEL (ASSY)

REMOVAL

(Right Side)

(Left Side)

Cut with disc
Sander etc.

Cut with disc sander etc.

Cowl Top to Apron Brace

Cut with disc
Sander etc.

After removing the cowl top to apron brace,
remove the cowl top side panel.

BODY PANEL REPLACEMENT

RE-20

in.

15
20

0.59
0.79

INSTALLATION

(Left Side)

(Right Side)

Tack Weld (20 mm each)

Tack Weld
(20 mm each)

Assembly Mark

Tack Weld
(15 mm each)

When temporarily installing the new parts,
determine the installation position by the
assembly mark. Then, measure each part
in accordance with the body dimension
diagram.

BODY PANEL REPLACEMENT

RE-21

PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER

MANAGER AND COLLISION REPAIR TECHNICIANS

00408-03000-146

OLLISION

EPAIR

NFORMATION

FOR THE TOYOTA DEALER

TITLE:

PAINTLESS DENT REPAIR

SECTION:

EXTERIOR

BULLETIN # 146

MODELS:

TOYOTA, SCION AND LEXUS

DATE:

SEPTEMBER

2006

Toyota has developed the following guidelines for the use of “Paintless Dent
Repair” (PDR) procedures on all Toyota, Scion and Lexus vehicles.

PDR is used to reduce the cost of repairing minor dents and to avoid color match
and refinish issues that may arise. Be sure to choose your PDR service provider
carefully and always review their professional qualifications to ensure they are up
to date on the latest PDR techniques and procedures.

Repair Precautions

• Always refer to the specific vehicle schematic (available from your PDR provider)

for locations where PDR is possible.

• Pay close attention to the locations of accessories and subassemblies that may

utilize wire harnesses or drain hoses, etc.

• PDR is often complicated by panel contour, placement of reinforcements, and

location of electrical and mechanical components.

• PDR Technicians should be aware of and take the necessary precautions to

prevent damage to electrical and mechanical components while performing
PDR repairs.

General Repair Guidelines

• The PDR process should only be considered when the exterior paint surface

is not broken or cracked. A 30X power hand held microscope (available from
most body shop jobbers) should be used to determine if the paint surface
shows evidence of cracking.

• Pushing and prying on the back side of body panels can disrupt the factory

rust and corrosion protective coatings. PDR technicians must take steps to
prevent corrosion coating damage or restore it with approved equivalent
materials. PDR service companies performing PDR repairs should be
knowledgeable and capable of restoring corrosion protective coatings
damaged during PDR repairs.

PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER

MANAGER AND COLLISION REPAIR TECHNICIANS

00408-03000-146

• Prying, pushing, or pulling on body panels may cause stretching beyond the

flexible limits of the paint coatings causing delamination (paint coating
separation) or micro-cracking. These conditions may not be immediately
detectable (use a 30X magnifying hand-held microscope to inspect for
cracks).

Important: The PDR process uses special tools to access otherwise
inaccessible areas. Drilling of holes, prying away or cutting
reinforcements or welded structural components to gain access to perform
a PDR is strictly prohibited and, if done, may void the manufacturer’s
corrosion protection warranty.

• Using blocks or wedges between window moldings and door glass (for tool

access) is also prohibited. This process can damage window moldings and
reduce the factory designed-in pressure of the inner belt molding on the base of
the door glass.

• Window guard protectors must be used to protect window glass during PDR

operations.

Specific Repair Guidelines

• Panels with multiple dents, including hail damage, may be considered for

PDR as long as the original panel integrity (strength) is maintained. If a panel
exhibits any evidence of loss of strength due to the number of dents, the
panel should not be considered for PDR. If after performing a PDR repair the
panel exhibits evidence of loss of strength, the panel must be repaired using
conventional body shop processes.

• Round/oval dents may be removed if they are 2 inches or more away from

panel edges or body lines and are no larger than the diameter of a soft ball.

• Creases that are up to 4” long may be considered for removal.

Note:

sharp creases cannot be removed

using PDR.

• Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks,

fenders, and quarter panels may be considered, but extreme caution must be
used during this type of repair due to the higher potential of damaging the
paint surface. Remember

no broken paint

in.

4.5
4.6
5.0
6.5
9.2

0.177
0.181
0.197
0.256
0.362

FIT STANDARDS

After doors and the engine hood are installed, be sure to perform fit adjustment to prevent abnormal wind
noise and ensure a good appearance.

5.0 mm

4.5 mm

4.6 mm

9.2 mm

6.5 mm

5.0 mm

APPENDIX

AP-2

FOAMED MATERIAL APPLICATION AREAS

The sections shown in the figure below are
filled with foamed material to provide noise
insullation.
After repairing these sections or their periph-
eries, refill with foamed materials.
HINT:
1.

Use the service holes located on the
reverse side of the body panel to refill
with foamed materials.

When handling foamed material, follow
the directions of the material’s manufac-
turer.

NORMAL ROOF

APPENDIX

AP-4

SPORT ROOF

APPENDIX

AP-5

FRONT FENDER APRON (ASSY)

REMOVAL (With the radiator upper support removed.)

Cut with disc
sander etc.

BODY PANEL REPLACEMENT

RE-10

in.

0.59

Assembly Mark

INSTALLATION

Tack Weld (15 mm each)

Temporarily install the front fender and hood,
and check the fit.

When temporarily installing the new parts,
determine the installation position by the
assembly mark.

Measurements must be accurate with the
body dimension diagram, as this affects the
front wheel alignment.

BODY PANEL REPLACEMENT

RE-11

MEMO

RE-12

FRONT SIDE MEMBER (ASSY)

REMOVAL (With the front crossmember and front
fender apron removed.)

LH:

Front Side Member No. 3
Reinforcement

LH:

RH:
LH:

Replace the front side member No. 3 reinforce-
ment at the same time.

BODY PANEL REPLACEMENT

RE-17

INSTALLATION

Front Side Member

Front Side Member No. 3
Reinforcement

Front Side Member
Plate

Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.

HINT: Make sure each measurement is correct,
as this part affects the front wheel alignment.

Before temporarily installing the new front
side member, weld the front side member No.
3 reinforcement with standard points.

BODY PANEL REPLACEMENT

RE-18

INSTALLATION (Cont’d)

LH:

RH:
LH:

BODY PANEL REPLACEMENT

RE-19

in.

30
40
100
150

1.18
1.57
3.94
5.91

FRONT BODY PILLAR (CUT): SPORT ROOF

REMOVAL (With the cowl top side panel removed.)

(Cut and Join Location)

Cut with disc
sander etc.

Cut and Join
Location

150mm

Cut and Join Location
(Pillar outer Panel)

40 mm

100 mm

Cut and Join Location
(Cut Location for Supply Parts)

(Cut and Join Location)

30 mm

Front Body Pillar
Lower Gusset

Cut and join the part at the locations shown
above.

HINT:
1)

Cut the front body pillar outer panel at a 40 mm
(1.57in.) offset from the inner panel as shown.

The cut location of the rocker panel reinforce-
ment is made 30 mm (1.18 in.) to the front of the
rocker outer panel cut location, as shown.

The rocker panel reinforcement cut location is
made 100mm (3.94 in.) to the front of the outer
panel cut location, avoid damaging the No. 4
reinforcement.

BODY PANEL REPLACEMENT

RE-26

REMOVAL (Cont’d)

Cut and Join Location
(Rocker Panel Reinforcement)

After removing the front body pillar lower
gusset, remove the front body pillar.

BODY PANEL REPLACEMENT

RE-27

Before installing the outer panel, inner rein-
forcement, inner pillar and rocker panel rein-
forcement, assemble the parts and weld them
according to the standard number of welds as
shown above.

INSTALLATION

Front Body
Inner Pillar

Front Body
upper outer
Pillar

Rocker Panel
Reinforcement

Front Body Pillar
Reinforcement

Temporarily instal the new parts and measure
each part in accordance with the body dimen-
sion diagram.

BODY PANEL REPLACEMENT

RE-28

in.

20
100

0.79
3.94

Before welding the new parts, check the fit of
the front door, front fender and windshield
glass.

A 100mm (3.94 in.) wide access hole should
be made in the rocker outer panel. After butt
welding the rocker panel reinforcement, reat-
tach the rocker outer panel by welding.

INSTALLATION (Cont’d)

Tack Weld
(20 mm)

Butt Weld

Butt Weld
(Rocker Panel Reinforcement)

100mm

After installing the new parts, apply foamed
material.

HINT: For the foamed material application areas,
refer to page

AP-4

BODY PANEL REPLACEMENT

RE-29

FRONT APRON TO COWL SIDE UPPER
MEMBER (ASSY)

REMOVAL (With the front fender front apron removed.)

BODY PANEL REPLACEMENT

RE-8

INSTALLATION

(RH only)

Speed Meter Control Mounting Bracket

Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.

Temporarily install the front fender and hood,
and check the fit.

BODY PANEL REPLACEMENT

RE-9

in.

30
70
120

1.18
2.76
4.72

FRONT BODY PILLAR (CUT): Normal Roof

REMOVAL (With the cowl top side panel removed.)

Cut with disc
sander etc.

(Cut and Join Location)

Cut and Join
Location

70 mm

120 mm

Cut and Join Location
(Cut Location for Supply Parts)

(Cut and Join Location)

30 mm

Front Body Pillar Lower Gusset

After removing the front body pillar lower
gusset, remove the front body pillar.

Cut and join the parts at the locations shown
above.

HINT:
1)

Cut the front body pillar outer panel at a 120
mm (4.72in.) offset from the inner panel as
shown above right.

The cut location of the rocker panel reinforce-
ment is made 30mm (1.18in) to the front of the
rocker panel inner cut location, as shown.

BODY PANEL REPLACEMENT

RE-22

REMOVAL (Cont’d)

Cut and Join Location
(Rocker Panel Reinforcement)

BODY PANEL REPLACEMENT

RE-23

INSTALLATION

Front Body
Inner Pillar

Front Body
Upper Outer
Pillar

Front Body Pillar
Reinforcement

Rocker Panel
Reinforcement

Before installing the outer panel inner rein-
forcement, inner pillar and rocker panel rein-
forcement, assemble the parts and weld them
according to the standard number of welds as
shown above.

Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.

BODY PANEL REPLACEMENT

RE-24

in.

20
60

0.79
2.36

Before welding the new parts, check the fit
of the front door, front fender and windshield
glass.

A 60mm (2.36in.) wide access hole should
be made in the rocker outer panel. After butt
welding the rocker panel reinforcement reat-
tach the rocker outer panel by welding.

INSTALLATION (Cont’d)

Tack Weld (20mm)

Butt Weld

Butt Weld
(Rocker Panel
Reinforcement)

Butt Weld
(Pillar Outer
Panel)

60 mm

After installing the new parts, apply foamed
material.

HINT: For the formed material application areas,
refer to page

AP-4

BODY PANEL REPLACEMENT

RE-25

FRONT CROSSMEMBER (ASSY)

REMOVAL

BODY PANEL REPLACEMENT

RE-4

INSTALLATION

Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.

BODY PANEL REPLACEMENT

RE-5

FRONT DOOR OUTER PANEL (ASSY)

REMOVAL

Hemming Location

Disc Sander

After grinding off the hemming location,
remove the outer panel.

BODY PANEL REPLACEMENT

RE-30

in.

0.39

Before temporarily installing the new parts,
apply body sealer to the reinforcement, side
impact protection beam and back side of the
new parts.

HINT:
1)

Apply just enough sealer for the reinforce-
ment and side impact beam to touch the new
panel. Apply sealer evenly around the flange
area, about 10 mm (0.39 in.) from the edge,
as shown.

For other sealing points, refer to section AR.

INSTALLATION

Body sealer

about 10mm

Do not close the
drain hole.

Body sealer

Cloth Tape

Hemming Tool

Bend the flange hem about 30

with a ham-

mer and dolly, then fasten tightly with a hem-
ming tool.

HINT:
1)

Perform hemming in three steps, being care-
ful not to warp the panel.

If a hemming tool cannot be used, hem with
a hammer and dolly.

BODY PANEL REPLACEMENT

RE-31

FRONT FENDER FRONT APRON (ASSY)

REMOVAL (With the radiator upper support removed.)

Apron Fender
Side Extension

Fender Side Apron

Replace the fender side apron and apron
fender side extension at the same time.

BODY PANEL REPLACEMENT

RE-6

INSTALLATION

Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.

BODY PANEL REPLACEMENT

RE-7

in.

50
70

1.97
2.76

FRONT SIDE MEMBER (CUT-P)

REMOVAL (With the radiator upper support and
front crossmember removed.)

70 mm

Cut and Join Location
(Inner Member and
Reinforcement)

50 mm

Cut and Join Location
(Outer Plate)

Cut and join the parts at the location shown
above.

HINT: Shift the cut and join location of the outer
plate, inner member and reinforcement.

BODY PANEL REPLACEMENT

RE-13

INSTALLATION

Butt Weld
(Inner Member)

Butt weld
(Reinforcement)

Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.

After butt welding the inner member and
reinforcement, install the outer plate.

BODY PANEL REPLACEMENT

RE-14

in.

0.39

INSTALLATION (Cont’d)

Outer Plate

Continuous
MIG Weld
(Outer Plate)

New Parts

about 10 mm

Flange

Continuous
MIG Weld

Front Side
Member Plate

Provide a flange of about 10 mm (0.39 in.) on
the new outer plate, then overlap it with the
vehicle side panel and weld them with a con-
tinuous MIG weld to the edge.

BODY PANEL REPLACEMENT

RE-15

MEMO

RE-16

BO6850
BO6850

mm (in.)

Imaginary
Standard
Line

(Two-Dimensional Distance)

Imaginary
Standard
Line

(Three-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Steering gear box installation hole front

12 (0.47)

E, e

Lower arm installation hole-front

(0.98

0.63)

B, b

Upper arm installation hole front

14 (0.55)

F, f

Lower arm installation hole rear

(0.98

0.63)

C, c

Suspension crossmember installation
hole front-lower

15 (0.59)

G, g

Upper arm installation hole rear

14 (0.55)

D, d

Steering gear box installation hole-
lower

12 (0.47)

H, h

Suspension crossmember installation
hole rear-lower

RH 15

(0.59 x 0.51)
LH 13 (0.51)

FRONT SUSPENSION CROSSMEMBER

BODY DIMENSIONS

DI-10

mm (in.)

BO8851
BO6851

Imaginary
Standard
Line

(Two-Dimensional Distance)

Imaginary
Standard
Line

(Three-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

I, i

Suspension crossmember installation
hole front-lower

18 (0.71)

L, l

Suspension crossmember installation
hole rear-lower

18 (0.71)

J, j

Lower arm installation hole-front

(1.18

0.63)

M, m

Suspension crossmember installation
hole rear-lower

18 (0.71)

K, k

Lower arm installation hole rear

(1.18 x 0.63)

FRONT SUSPENSION CROSSMEMBER (Cont’d)

BODY DIMENSIONS

DI-11

GENERAL INFORMATION

Anti-rust treatment is necessary before welding and before and after the painting process.

ANTI-RUST TREATMENT BEFORE WELDING

Weld-Through Primer
(Spot Sealer)

WELD-THROUGH PRIMER (SPOT SEALER)
APPLICATION

For anti-corrosion measures, always apply the
weld-through primer (spot sealer) to welding sur-
faces where the paint film has been removed.
HINT: Apply the weld-through primer (spot
sealer) to that it does not ooze out from the joining
surfaces.

WELD-THROUGH PRIMER (SPOT SEALER)
APPLICATION

ANTI-RUST TREATMENT BEFORE PAINTING PROCESS

Sealer Gun

BODY SEALER APPLICATION

For water-proofing and anti-corrosion measures,
always apply the body sealer to the body panel
seams and hems of the doors, etc.

BODY SEALER APPLICATION

UNDERCOAT APPLICATION

To prevent corrosion and protect the body from
damage by flying stones, always apply sufficient
undercoat to the bottom surface of the under body
and inside of the wheel housings.

UNDERCOAT APPLICATION

ANTI-RUST TREATMENT

AR-2

Steel Metal

Undercoat (ED Primer)

Anti-Chipping Paint

Second Coat

Steel Metal

Undercoat (ED Primer)

Second Coat

Top Coat

ANTI-RUST TREATMENT AFTER PAINTING PROCESS

ANTI-RUST AGENT (WAX) APPLICATION

To preserve impossible to paint areas from
corrosion, always apply sufficient anti-rust
agent (wax) to the inside of the hemming
areas of the doors and hoods, and around the
hinges, or the welded surfaces inside the
boxed cross-section structure of the side
member, body pillar, etc.

ANTI-RUST AGENT (WAX) APPLICATION

REFERENCE: ANTI-RUST TREATMENT BY PAINTING

Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint
only for anti-corrosion purpose is described.

ANTI-CHIPPING PAINT

To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint
to the rocker panel, wheel arch areas, valance panel, etc.
HINT:
Depending on the model or the application area, there are cases where the application of anti-chipping
paint is necessary before the second coat or after the top coat.

Apply the anti-chipping paint
before the second coat.

Apply the anti-chipping paint
after the top coat.

Anti-Chipping Paint

Top Coat

ANTI-RUST TREATMENT

AR-3

GENERAL INFORMATION

BASIC DIMENSIONS

(a)

There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.

(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.

(b)

In cases in which only one dimension is given, left
and right are symmetrical.

(c)

The dimensions in the following drawing indicate
actual distance. Therefore, please use the dimen-
sions as a reference.

MEASURING

(a)

Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.

(b)

Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.

HINT:
1.

The height of the left and right pointers must be equal.

Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.

Take care not to drop the tracking gauge or otherwise
shock it.

Confirm that the pointers are securely in the holes.

(c)

When using a tape measure, avoid twists and
bends in the tape.

(d)

When tracking a diagonal measurement from the
front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.

Center-to-center
straight-line
distance

Three-dimensional
distance

Front Spring Support Inner Hole

Tape Measure

Along Body
Surface

Front Suspension Member Rear Side
Upper Installation Hole

Master Gauge

Pointer

Pointer Looseness

Body Looseness

Plate Looseness

Two-dimensional
distance

Center-to-center
Horizontal distance in
forward/rearward

Vertical distance
in lower surface

Vertical distance
in center

Imaginary Standard Line

Wrong

Correct

Pointer

BODY DIMENSIONS

DI-2

Code

Material

name

Heat*

resistant

temperature

limit

C (

Resistance to

alcohol or gasoline

Notes

AAS

Acrylonitrile
Acrylic Styrene

(176)

Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid gasoline and
organic or aromatic
solvents.

ABS

Acrylonitrile
Butadiene Styrene

(176)

Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid gasoline and
organic or aromatic
solvents.

AES

Acrylonitrile
Ethylene Styrene

(176)

Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid gasoline and
organic or aromatic
solvents.

BMC

Bulk
Moulding
Compound

150

(302)

Alcohol and gasoline are
harmless.

Most solvents are
harmless.

CAB

Cellulose
Acetate

(176)

Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid gasoline and
organic or aromatic
solvents.

EPDM

Ethylene
Propylene

100

(212)

Alcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.

Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.

Polyamide
(Nylon)

(176)

Alcohol and gasoline are
harmless.

Avoid battery acid.

PBT

Polybutylene
Terephthalate

160

(320)

Alcohol and gasoline are
harmless.

Most solvents are
harmless.

Polycarbonate

120

(248)

Alcohol is harmless.

Avoid gasoline, brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.

Polyethylene

(176)

Alcohol and gasoline are harmless.

Most solvents are
harmless.

PET

Polyethylene
Terephthalate

(176)

Alcohol and gasoline are
harmless.

Avoid dipping in water.

HANDLING PRECAUTIONS

The repair procedure for plastic body parts must conform with the type of plastic material.

Plastic body parts are identified by the codes in the following chart.

When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.

* Temperatures higher than those listed here may result in material deformation during repair.

PLASTIC BODY PARTS

PP-2

Code

Material

name

Heat*

resistant

temperature

limit

C (

Resistance to

alcohol or gasoline

Notes

PMMA

Polymethyl
Methacrylate

(176)

Alcohol is harmless if applied
only for short time in small
amounts.

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

POM

Polyoxymethylene
(Polyacetal)

100

(212)

Alcohol and gasoline are
harmless.

Most solvents are
harmless.

Polypropylene

(176)

Alcohol and gasoline are
harmless.

Most solvents are
harmless.

PPO

Modified
Polyphenylene
Oxide

100

(212)

Alcohol is harmless.

Gasoline is harmless if
applied only for quick
wiping to remove
grease.

Polystyrene

(140)

Alcohol and gasoline are
harmless if applied only for
short time in small amounts.

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

PUR

Polyurethane

(176)

Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

PVC

Polyvinylchloride
(Vinyl)

(176)

Alcohol and gasoline are harmless
if applied only for short time in small
amounts (e.g., quick wiping to re-
move grease).

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

SAN

Styrene
Acrylonitrile

(176)

Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

SMC

Sheet
Moulding
Compound

180

(356)

Alcohol and gasoline are
harmless.

Avoid alkali.

TPO

Thermoplastic
Olefine

(176)

Alcohol is harmless.
Gasoline is harmless if applied
only for short tune in small
amounts.

Most solvents are
harmless but avoid dip-
ping in gasoline, sol-
vents, etc.

TPU

Thermoplastic
Polyurethane

(176)

Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).

Avoid dipping or im-
mersing in alcohol,
gasoline, solvents,
etc.

TSOP

TOYOTA
Supper
Olefine Polymer

(176)

Alcohol and gasoline are
harmless.

Most solvents are
harmless.

Unsaturated
Polyester

110

(233)

Alcohol and gasoline are
harmless.

Avoid alkali.

* Temperatures higher than those listed here may result in material deformation during repair.

PLASTIC BODY PARTS

PP-3

High-Strength Steel

HIGH-STRENGTH STEEL (HSS) PARTS

Generally, High-Strength Steel (HSS) is that which has an intensity value of at 35 kgf/mm

(343 MPa),

and distinguished from mild steel.

The handling of HSS is the same as for mild steel, but the following should be observed.

Panel Hammering: Because HSS is thinner than mild steel, care should be taken to avoid warping
during hammering operations.

Removing Spot Welds: Because HSS is tougher than mild steel, damage will occur more easily to
a regular drill. Therefore, an HSS Spot Cutter is recommended.
Also, use a high-torque drill at low speed, and supply grinding oil to the drill during use.

Panel Welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug
welding should be done with MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at
areas other than specified.

BODY PANEL CONSTRUCTION

CN-3

LOCATION OF PLASTIC BODY PARTS

Outer Rear View Mirror (ABS)

Front Door Outside Handle (PC)

Instrument Panel Safety Pad (PVC/PUR)

Rear Spoiler (SMC/UP)

Cowl Top Ventilator Louver (PP)

Hood Bulge (BMC)
<For General>

Headlamp (PC/PP)

Quarter Lower
Moulding (PP)

Quarter Panel Air Inlet
Garnish (PUR)

Body Rocker Panel Moulding (PP)

Front Bumper Extension
Mounting Bracket (PP)

Front Fender Moulding (PP)

Side Turn Signal Lamp (SAN/ABS)
<For General>

Front Spoiler Cover (PUR)

Front Side Marker Lamp (PMMA/ABS)
<For U.S.A & CANADA>

Front Turn Signal Lamp (PMMA/PP)

Front Bumper Cover (PUR)

Front Active Spoiler (PUR)

HINT:

•

Resin material differs with model.

/ Made up of 2 or more kinds of materials.

PLASTIC BODY PARTS

PP-4

Roof Side Inner Garnish (PP)

Rear Speaker Grille (ABS/PET)

Quarter Inside Trim Board (PP)

Front Pillar Garnish (PP)

Cowl Side Trim (PP/PE)

Radiator Upper Air
Deflector (PP/PE)

Front Door Scuff Outside Plate (PP)

Front Fender Liner (PE)

Radiator
Reserver Tank (PP)

Windshield Washer Jar (PP)

Front Fender splash shield (PE)

Engine Under No. 1 Cover (PP/PE)

Engine Under No. 4 Cover (PE)

Engine Under No. 2 Cover (PE)

HINT:

•

Resin material differs with model.

/ Made up of 2 or more kinds of materials.

PLASTIC BODY PARTS

PP-5

Steering Wheel Pad (PUR)

Quarter Wheel Housing Inner Cover (PP)

Rear Combination Lamp (PMMA/PC/PP)

Instrument Panal Passenger
Air Bag (PVC/PUR)

Center Stop Lamp (PMMA/ABS)

Deck Trim Side Board (PP)

Quarter Vent Duct (PP)

Front Fender
Mudguard (PP)

Air Conditioner Unit (PP)

Licence Plate Lamp (PC/PP)

Rear Bumper Cover (PUR)

Fuel Filler Opening Lid (PBT)

Rear Side Marker
Lamp (PMMA/ABS)
<For U.S.A & CANADA>

Fuel Tank Filler
Pipe Protector
(PE)

Back Door Trim Board (PP/PE)

Fuel Tank (PE)

Deck Trim Rear Cover (PP/PE)

HINT:

•

Resin material differs with model.

/ Made up of 2 or more kinds of materials.

PLASTIC BODY PARTS

PP-6

QUARTER PANEL (CUT-P)

REMOVAL

Cut and Join
Location

Cut and join the parts at the location shown
above.

BODY PANEL REPLACEMENT

RE-38

in.

0.20

Temporarily install the new parts and check
the fit of the back door and rear combination
lamp.

Before welding, cut the lining away from the
weld seams a little.

INSTALLATION

Butt Weld

Body Sealer

Braze

Butt Weld

Braze

Body Sealer

about 5 mm

Before temporarily installing the new parts,
apply body sealer to the wheel arch.

HINT:
1)

Apply body sealer about 5 mm (0.20 in.) from
the flange, avoiding any oozing.

Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) diameter.

For other sealing points, refer to section AR.

BODY PANEL REPLACEMENT

RE-39

in.

120

4.72

QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Normal Roof Left Side

REMOVAL (With the quarter panel removed.)

Cut and Join
Location

Roof Side inner to
Wheel Housing Brace

120mm

Rocker Panel
Reinforcement

Cut and Join
Location

Cut the roof side inner to wheel housing
brace and the rocker panel reinforcement
end at locations shown above. Remove the
quarter wheel housing outer panel.

BODY PANEL REPLACEMENT

RE-42

INSTALLATION

Butt Weld

Assembly Mark

Determine the position of the new parts by the
assembly marks of the inner and outer panels.

BODY PANEL REPLACEMENT

RE-43

in.

120

4.72

QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Sport Roof Right Side

REMOVAL (With the quarter panel removed.)

Cut and Join Location

Roof Side Inner to
Wheel Housing Brace

120 mm

Cut and Join Location

Rocker Panel Reinforcement

Cut the roof side inner to wheel housing brace
and the rocker panel reinforcement end at the
locations shown above. Remove the quarter
wheel housing outer panel.

BODY PANEL REPLACEMENT

RE-44

INSTALLATION

Butt Weld

Assembly Mark

Butt Weld

Determine the position of the new parts by the
assembly marks of the inner and outer panels.

BODY PANEL REPLACEMENT

RE-45

in.

120

4.72

QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Sport Roof Left Side

REMOVAL (With the quarter panel removed.)

Cut and Join Location

Roof Side Inner to heel
Housing Brace

120 mm

Rocker Panel
Reinforcement

Cut and Join
Location

Cut the roof side inner to wheel housing brace
and the rocker panel reinforcement end at the
location shown above. Remove the quarter
wheel housing outer panel.

BODY PANEL REPLACEMENT

RE-46

INSTALLATION

Butt Weld

Assembly Mark

Butt Weld

Determine the position of the new parts by the
assembly marks of the inner and outer panels.

BODY PANEL REPLACEMENT

RE-47

QUARTER INNER PANEL (CUT-P): Left Side

REMOVAL (With the quarter panel and body lower
back panel removed.)

Cut and Join Location

Cut and join the parts at the location as shown
above.

BODY PANEL REPLACEMENT

RE-52

Overlap the new parts 20 mm (0.79 in.) at the
locations and spot weld.

INSTALLATION

For overlapping areas apply sealer to both
sides.

HINT: For other sealing points, refer to section
AR.

BODY PANEL REPLACEMENT

RE-53

QUARTER INNER PANEL (CUT-P): Right Side

REMOVAL (With the quarter panel and body lower
back panel removed.)

Cut and Join Location

Cut and join the parts at the location as shown
above.

BODY PANEL REPLACEMENT

RE-50

INSTALLATION

Overlap the new parts 20 mm (0.79 in.) at
the cut locations and spot weld.

For overlapping areas, apply sealer to both
sides.

HINT: For other sealing points, refer to section
AR.

BODY PANEL REPLACEMENT

RE-51

in.

100
200

3.94
7.87

QUARTER PANEL (CUT)

REMOVAL

(Cut and Join Location)

200 mm

(Cut and Join Location)

Cut and Join Location

100 mm

Cut and Join
Location

Cut and Join Location
(Cut Location for Supply Parts)

Sport Roof

Normal Roof

Cut and join the parts at the location shown
above.

(Cut and Join Location)

BODY PANEL REPLACEMENT

RE-34

REMOVAL (Cont’d)

Normal Roof:

Sport Roof:

BODY PANEL REPLACEMENT

RE-35

in.

0.20

Before temporarily installing the new parts,
apply body sealer to the wheel arch.

HINT:
1)

Apply body sealer about 5 mm (0.20 in.) from
the flange, avoiding any oozing.

Apply sealer evenly, about 3 - 4 mm (0.12 -
0.16 in.) in diameter.

For other sealing points, refer to section AR.

INSTALLATION

Butt Weld

Body Sealer

Butt Weld

Body Sealer

about 5 mm

Normal Roof:

Temporarily install the new parts and check the
fit of the front door, back door and rear com-
bination lamp.

Apply foamed material to the pillar section.

HINT: For the foamed material application areas,
refer to page

AP-4

Sport Roof:

BODY PANEL REPLACEMENT

RE-36

INSTALLATION (Cont’d)

Braze

BODY PANEL REPLACEMENT

RE-37

in.

120

4.72

QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Normal Roof Right Side

REMOVAL (With the quarter panel removed.)

Cut and Join Location

Roof Side Inner to
Wheel Housing Brace

120 mm

Rocker Panel
Reinforcement

Cut and Join
Location

Cut the roof side inner to wheel housing brace
and the rocker panel reinforcement end at the
locations noted above. Remove the quarter
wheel housing outer panel.

BODY PANEL REPLACEMENT

RE-40

INSTALLATION

Butt weld

Butt Weld

Assembly Mark

Determine the position of the new parts by the
assembly marks of the inner and outer panels.

BODY PANEL REPLACEMENT

RE-41

RADIATOR UPPER SUPPORT (ASSY)

REMOVAL

BODY PANEL REPLACEMENT

RE-2

INSTALLATION

Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.

HINT: First install the hood lock support.

BODY PANEL REPLACEMENT

RE-3

REAR FLOOR PAN TO QUARTER PANEL
EXTENSION (ASSY)

REMOVAL (With the body lower back panel removed.)

(Right Side)

(Left Side)

Push down on the rear floor pan to quarter
panel extension and remove it.

BODY PANEL REPLACEMENT

RE-56

(Left Side)

INSTALLATION

(Right Side)

BODY PANEL REPLACEMENT

RE-57

in.

0.79

REAR FLOOR SIDE REAR MEMBER (ASSY)

20 mm

REMOVAL (With the rear floor pan and rear floor pan to
quarter panel extension removed.)

Cut and Join Location
(Rear Floor Side Member
Reinforcement)

Cut with disc
sander etc.

Cut out the rear floor side member reinforce-
ment at the cut location indicated above.

BODY PANEL REPLACEMENT

RE-58

in.

0.98

INSTALLATION

LH:

Butt Weld
(Rear Floor Side Member
Reinforcement)

Assembly Mark

Tack Weld
(25 mm each)

When temporarily installing the new parts,
determine the installation position by the
assembly mark. Then, measure each part
in accordance with the body dimension
diagram.

RH:

LH:

RH:

LH:

RH:

BODY PANEL REPLACEMENT

RE-59

REAR FLOOR NO. 2 CROSSMEMBER (ASSY)

REMOVAL

BODY PANEL REPLACEMENT

RE-60

INSTALLATION

Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.

BODY PANEL REPLACEMENT

RE-61

REAR FLOOR PAN (ASSY)

REMOVAL (With the body lower back panel removed.)

BODY PANEL REPLACEMENT

RE-54

INSTALLATION

BODY PANEL REPLACEMENT

RE-55

NO8909
NO8909

mm (in.)

Imaginary
Standard
Line

(Three-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Strut rod installation hole-inner

14.2

(0. 559)

F, f

No. 2 lower arm installation hole-front

14.2

(1.02

0.559)

B, b

Differential carrier installation nut

12 (0.47)

nut

G, g

Rear suspension member standard hole

20 (0.79)

C, c

Rear suspension member standard hole

20 (0.79)

H, h

Upper arm installation hole-rear

14.2

(0.559)

D, d

No. 1 lower arm installation hole-front

26x 14.2

(1.02

0.559)

I, i

No. 2 lower arm installation hole-rear

14.2

(1.02

0.559)

E, e

Upper arm installation hole-front

14.2

(0.559)

REAR SUSPENSION CROSSMEMBER

BODY DIMENSIONS

DI-12

mm (in.)

NO8909
NO8909

Imaginary
Standard
Line

(Two-Dimensional Distance)

Symbol

Name

Hole dia.

Symbol

Name

Hole dia.

A, a

Strut rod installation hole-inner

14.2

(0.559)

F, f

No. 2 lower arm installation hole-front

14.2

(1.02

0.559)

B, b

Differential carrier installation nut

12 (0.47)

nut

G, g

Rear suspension member standard hole

20 (0.79)

C, c

Rear suspension member standard hole

20 (0.79)

H, h

Upper arm installation hole-rear

14.2

(0.559)

D, d

No. 1 lower arm installation hole-front

14.2

(1.02

0.559)

I, i

No. 2 lower arm installation hole-rear

14.2

(1.02

0.559)

E, e

Upper arm installation hole-front

14.2

(0.559)

REAR SUSPENSION CROSSMEMBER (Cont’d)

BODY DIMENSIONS

DI-13

ROCKER OUTER PANEL (CUT)

REMOVAL

Cut and Join Location
(Cut Location for Supply Parts)

Normal Roof:

Sport Roof:

(Cut and Join Location)

Normal Roof

Sport Roof

Cut and join the parts at the location as shown
above.

HINT:
1)

Be careful to cut so the rocker panel reinforce-
ment is not damaged.

BODY PANEL REPLACEMENT

RE-32

INSTALLATION

Butt Weld

Normal Roof:

Sport Roof:

Temporarily install the new parts and check
the fit of the front door.

BODY PANEL REPLACEMENT

RE-33

ROOF PANEL (ASSY): Sport Roof

REMOVAL

Braze
(both sides)

Heat the brazed area of the front body pillar
and quarter panel and scrape off the brazing
with a wire brush.

HINT: Be careful not to overheat the pillar sides.

BODY PANEL REPLACEMENT

RE-64

Braze the front body pillar and quarter panel
connection.

HINT: Before performing these operations, place
a wet rag on the roof panel to protect it from
damage.

INSTALLATION

Body Sealer

Braze
(both sides)

Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.

HINT:
1)

Apply just enough sealer for the new parts to
make contact.

For other sealing points, refer to Section AR.

BODY PANEL REPLACEMENT

RE-65

ROOF PANEL (ASSY): Normal Roof

REMOVAL

Braze
(both sides)

Heat the brazed area of the front body pillar
and quarter panel and scrape off the brazing
with a wire brush

HINT: Be careful not to overheat the pillar sides.

BODY PANEL REPLACEMENT

RE-62

Braze the front body pillar and quarter panel
connection.

HINT: Before performing these operations, place
a wet rag on the roof panel to protect it from
damage.

INSTALLATION

Body Sealer

Braze
(both sides)

Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.

HINT:
1)

Apply just enough sealer for the new parts to
make contact.

For other sealing points, refer to Section AR.

BODY PANEL REPLACEMENT

RE-63

Galvannealed Sheet Steel

Excelite II

RUST-RESIST ANT SHEET STEEL PARTS

Rust-Resistant Sheet Steel have zinc, tin or aluminum etc, plating over the base metal surface in order to
improve the corrosion resistance of the sheet metal. For the vehicle’s body panels, galvannealed sheet
steel is widely used.
Body panel on TOYOTA models are made of two different galvannealed sheet steel. The ordinary galvan-
nealed sheet steel has a zinc-iron alloy plating over the base metal surface. Zinc-iron alloy double-layer
galvannealed sheet steel has zinc-iron alloy plating on both the outside and the back surface, plus a fur-
ther iron-rich zinc-iron alloy plating which has good paint adhesion. These two galvannealed sheet steels
are used selectively according to need.

Zn-Fe Alloy (Iron Rich) improves
paint quality

Zn-Fe Alloy
(Zinc-Rich)

Zn-Fe Alloy (Zinc Rich) improves
rust-resistant performance

Base Metal

Base
Metal

Galvannealed Sheet Steel

Excelite II

The handing of Rust-Resistant Sheet Steel is the same as for ordinary sheet steel, but the following
should be observed.
1.

Panel Welding: The paint as well as the zinc portion must be removed completely from the welding
area to guarantee good welding integrity.

Anti-Rust Treatment: Since the zinc plating is lost after welding, anti-rust treatment of the welded
area must be thoroughly performed (refer to section AR).

BODY PANEL CONSTRUCTION

CN-4

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

SCRATCH–RESISTANT PAINT

PAGE 1 of 2

SECTION:

REFINISH

BULLETIN #78

MODELS:

JAPAN PRODUCED VEHICLES (AS LISTED)

DATE:

AUGUST 1997

Some Toyota models produced in Japan are finished with a Scratch–Resistant paint
technology. This type of coating provides improved resistance to minor scratching. Vehicles
produced with this type of coating can be identified by referring to the chart below and by
the Vehicle Identification Number (VIN). The first character in the VIN of Japan–built
vehicles is a “J” (J=Japan).

NOTE: U.S. manufactured vehicles do not use this type of paint technology.

Model

Color Code

Date of Introduction

Camry

202

August 1992

Celica

202

August 1991

MR2

202

December 1989

LandCruiser

202

December 1995

RAV4

202

January 1995

Supra

202

April 1993

Color code 202 (Black) is a single–stage paint as applied by the factory. During refinish
work however, two–stage (basecoat/clearcoat) refinishing utilizing the appropriate
materials is recommended.

REFINISH RECOMMENDATIONS

Refinish materials that provide similar scratch–resistant qualities have been developed by
your respective paint vendor. Listed are the refinish materials (basecoat, clearcoat,
reducer, hardener/activator) recommended by Toyota and your paint vendor for refinishing
vehicles originally manufactured with scratch–resistant paint.

SCRATCH–RESISTANT PAINT (cont’d)

PAGE 2 of 2

Manufacturer

Basecoat

Clearcoat

Reducer

Hardener/Activator

Akzo–Nobel

Autobase

Autocoat LV HS

Autocoat LV

Hardener HS–BSR

BASF

54/55 line

923–43

none

929–76

DuPont

Chroma–base

9700S

1085S

3575S

ICI Autocolor

2K/Aquabase

P190–639

P850–1692/3/4

P210–839

PPG

Deltron 2000

Global BC

DCU 2021

D894

DT–Series

D807

DCX8

D897

Sherwin–Williams

Martin Senour

Ultra–7000

Tec/Base

CC–830 HS

8895 HS

CCR–837

8879

UH–100 HS

8874

Spies–Hecker

Permacron

293/295

Permasolid 8030

Permacron

Series

3120 Super Hardener

Standox

Basecoat

2K HS Clear

2K Thinner

Scratch–Resistant

Check with your paint vendor for VOC compliance information and product availability.

Contact your paint vendor for additional information on application procedures, material
availability and VOC compliant materials. For paint vendor technical service information
telephone numbers, refer to Collision Repair Information Bulletin #77.

POLISHING TIPS

Follow paint vendor recommended baking or air dry times prior to sanding and polishing.

Since this type of paint technology resists scratches, it is important to understand that
sanding and polishing to remove dirt nibs may require additional time.

Use a fine grit sand paper (2000–2500 grit) soaked in a soapy water solution for a
minimum of 1–hour (overnight preferred) to prevent deep scratches and use polishing
materials designed for urethane–type clearcoats.

SILENCER SHEET INSTALLATION AREAS

Thickness of Asphalt Sheet

1.5 mm

. . . . . . .

(0.059 in.)

APPENDIX

AP-3

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

SRS AIRBAG COMPONENT REPLACEMENT

PAGE 1 of 6

SECTION:

ELECTRICAL BULLETIN #79

MODELS:

ALL

DATE:

AUGUST 1997

After an airbag has been deployed during a collision, it will be necessary to replace certain
components of the airbag system. Technicians can identify these parts by using the
attached matrix.

If the airbag does not deploy, yet the combination meter (airbag warning light) stays on for
more that 10 seconds after the key is turned to the “ACC” or “ON” position, it is necessary
to perform a diagnostic test. Always refer to the Toyota repair manual for the correct repair
procedure.

The attached information includes:

A matrix indicating components requiring replacement (pages 2–4).

Parts replacement note (page 5).

An example repair manual page outlining the diagnostic procedure available in
each model specific repair manual (page 6).

Toyota recommends the use of electrical repair kit (P/N 00002–04200–01) for any wiring
repairs. This kit includes a selection of numerous repair connectors, terminal ends, a repair
procedures manual and special tools specific to Toyota. The

replacement electrical wire

and connector (from the wire harness to the front sensors) is P/N 82988–24010.

Toyota also offers a video package which shows the operation of the SRS airbag system
(P/N 00401–42994).

CAUTION: SRS Airbag service work can be performed only AFTER 90 SECONDS

from the time the ignition switch is turned to the “lock” position and the
negative (–) terminal cable is disconnected from the battery.

NOTE: PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
MANAGER!

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 2 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 3 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 4 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 5 of 6

Component Replacement Notes

Note 1 –

Replace the following items:

Instrument panel

Center console bracket support

Note 2 –

Replace the following items if deformed:

Instrument panel

Instrument panel reinforcement

Glove compartment

Glove compartment door

Note 3 –

Replace the following items:

Instrument panel reinforcement

Glove compartment

Glove compartment door

Note 3a –

Replace the following items:

Instrument panel

Instrument panel reinforcement

Glove compartment door

Note 4 –

If the SRS wire harness assembly is damaged:

Use a repair wire specially designed for use in the SRS airbag system at the front
sensor (P/N 82988–24010).
OR

Replace the entire wire harness assembly.

Note 4a –

Replace wire harness if damaged.

Repair only if wire harness connector is damaged.

Note 4b –

Replace wire harness if damaged.

Note 5 –

Replace the following items if deformed:

Steering wheel

Spiral cable

Note 6 –

Replace center airbag sensor assembly if:

Center airbag sensor assembly has been found faulty in troubleshooting

Center airbag sensor assembly has been found faulty during the following checks:
1. Deformation of the bracket or case
2. Vinyl seal broken
3. Damage to connector

Center airbag sensor assembly has been dropped.

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 6 of 6

This is an example from a Toyota Repair Manual. Always refer to the repair manual
applicable to the model and year vehicle you are diagnosing.

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

SRS AIRBAG COMPONENT REPLACEMENT

PAGE 1 of 4

SECTION:

ELECTRICAL

BULLETIN #83

MODELS:

ALL

DATE:

MAY 1998

After an airbag has been deployed during a collision, it will be necessary to replace certain
components of the SRS system. Technicians can identify these parts by using the attached
matrix.

If, after the vehicle has been completely repaired, the airbag warning light stays on for
more than 6 seconds while the key is turned to the “ACC” or “ON” position, it is necessary
to perform a diagnostic test. Always refer to the model–specific Toyota Repair Manual for
the correct repair procedure.

The attached information includes:

A matrix indicating components requiring replacement (page 3).

Parts replacement notes (page 4).

An example Repair Manual page outlining the diagnostic procedure available in
each model–specific Repair Manual (page 2).

On some vehicles the front sensors may be replaced. Please refer to the model–specific
repair manual concerning front airbag sensor replacement requirements before performing
this repair. Three part numbers are available for

replacement electrical wire and

connectors from the wire harness to the front SRS sensors. They are P/N 82988–24010,
82988–50010, and 82988–33010.

Toyota also offers a video package which outlines the operation of the SRS airbag system
(P/N 00401–42994).

NOTE: PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
MANAGER!

SRS COMPONENT REPLACEMENT (cont’d)

PAGE 2 of 4

CAUTION: SRS Airbag service work can be performed only AFTER 90 SECONDS

from the time the ignition switch is turned to the “lock” position and the
negative (–) terminal cable is disconnected from the battery.

This is an example from a Toyota Repair Manual. Always refer to the repair manual
applicable to the model and year of the vehicle you are diagnosing.

SRS COMPONENT REPLACEMENT (cont’d)

PAGE 3 of 4

SRS COMPONENT REPLACEMENT (cont’d)

PAGE 4 of 4

Component Replacement Notes

Note 1 –

Visually inspect and replace the following items if deformed:

Instrument panel and center console bracket support

Note 2 –

Visually inspect and replace the following items if deformed:

Instrument panel and Instrument panel reinforcement

Glove compartment and glove compartment door

Note 2a –

Same as note 2 without involving the glove compartment.

Note 3 –

If the SRS wire harness is damaged only at the connectors to the front
sensors:

Use a repair wire specially designed for use in the SRS airbag system at the front sensor
(PN 82988–24010/50010/33010).
OR

Replace the entire wire harness assembly.

Note 3a –

Replace the entire wire harness if damaged or has been found to be faulty
during troubleshooting.

Note 4 –

Replace the following items if deformed or if diagnostic tests show a fault:

Steering wheel (If the horn button contact plate has been deformed, never attempt to
repair it–always replace the steering wheel).

Spiral cable

Note 5 –

Replace center airbag sensor assembly if:

Center airbag sensor assembly has been found faulty in troubleshooting.

Center airbag sensor assembly shows evidence of the following:

1. Deformation of the bracket or case
2. Vinyl seal broken
3. Damage to connector

Center airbag sensor assembly has been dropped.

Note 6 –

Replace side impact sensors and side airbag assembly with seat cover if
deployed. Side airbag circuits are independent from each other, and one
side may deploy while the other does not.

Note 7 –

1998 Tacoma is equipped with a passenger airbag cutoff switch. If the
switch is “OFF” when impact occurs, replace the switch. If the switch is in
the “ON” position when impact occurs, and the passenger airbag deploys,
check the switch as directed by the Repair Manual.

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

SRS AIRBAG COMPONENT REPLACEMENT

PAGE 1 of 6

SECTION:

ELECTRICAL BULLETIN #79

MODELS:

ALL

DATE:

AUGUST 1997

After an airbag has been deployed during a collision, it will be necessary to replace certain
components of the airbag system. Technicians can identify these parts by using the
attached matrix.

The attached information includes:

A matrix indicating components requiring replacement (pages 2–4).

Parts replacement note (page 5).

An example repair manual page outlining the diagnostic procedure available in
each model specific repair manual (page 6).

replacement electrical wire

and connector (from the wire harness to the front sensors) is P/N 82988–24010.

Toyota also offers a video package which shows the operation of the SRS airbag system
(P/N 00401–42994).

CAUTION: SRS Airbag service work can be performed only AFTER 90 SECONDS

from the time the ignition switch is turned to the “lock” position and the
negative (–) terminal cable is disconnected from the battery.

NOTE: PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
MANAGER!

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 2 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 3 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 4 of 6

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 5 of 6

Component Replacement Notes

Note 1 –

Replace the following items:

Instrument panel

Center console bracket support

Note 2 –

Replace the following items if deformed:

Instrument panel

Instrument panel reinforcement

Glove compartment

Glove compartment door

Note 3 –

Replace the following items:

Instrument panel reinforcement

Glove compartment

Glove compartment door

Note 3a –

Replace the following items:

Instrument panel

Instrument panel reinforcement

Glove compartment door

Note 4 –

If the SRS wire harness assembly is damaged:

Use a repair wire specially designed for use in the SRS airbag system at the front
sensor (P/N 82988–24010).
OR

Replace the entire wire harness assembly.

Note 4a –

Replace wire harness if damaged.

Repair only if wire harness connector is damaged.

Note 4b –

Replace wire harness if damaged.

Note 5 –

Replace the following items if deformed:

Steering wheel

Spiral cable

Note 6 –

Replace center airbag sensor assembly if:

Center airbag sensor assembly has been found faulty in troubleshooting

Center airbag sensor assembly has been found faulty during the following checks:
1. Deformation of the bracket or case
2. Vinyl seal broken
3. Damage to connector

Center airbag sensor assembly has been dropped.

SRS AIRBAG COMPONENT REPLACEMENT (cont’d)

PAGE 6 of 6

This is an example from a Toyota Repair Manual. Always refer to the repair manual
applicable to the model and year vehicle you are diagnosing.

in.

5
10
13
18
22

0.20
0.39
0.51
0.71
0.86

Center Mark

STANDARD BODY MARKS

Center Mark (5

)

Assembly Mark

Center Mark

Assembly Mark

BODY PANEL CONSTRUCTION

CN-2

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

TOYOTA COLLISION REPAIR &

PAGE 1 of 5

REFINISH SERVICE PUBLICATIONS

SECTION:

GENERAL INFORMATION BULLETIN #75

MODELS:

ALL

DATE:

JANUARY 1997

Toyota Collision Repair and Refinish Service Publications are an integral part of the Toyota
philosophy of “fix it right the first time”. This detailed repair information is designed to
speed and simplify repair operations and improve the quality of each repair. For ordering
information, please refer to page 5 of this bulletin.

COLLISION REPAIR MANUALS

Cutting and welding operations

Anti–rust treatment

Body component diagrams and illustrations

SRS handling precautions

Body panel replacement

Electronic control unit (ECU) locations

Body dimensions

Plastic body part identification

Model

Year

Part Number

Price

AVALON
Collision Repair Manual

1997–95

00400–BR046

$20.00

CAMRY
Collision Repair Manual

1997

00400–BR062

20.00

Collision Repair Manual

1996–92

00400–BR032

9.00

Collision Repair Manual–Coupe

1996–94

00400–BR043

9.00

Collision Repair Manual–Wagon

1996–92

00400–BR035

9.00

Collision Repair Manual

1991–87

00400–BRM01–0E

8.95

Collision Repair Manual

1986–83

00400–36433–E

6.95

CELICA
Collision Repair Manual–Convertible

1997–94

00400–BR048

15.00

Collision Repair Manual

1997–94

00400–BR044

15.00

Collision Repair Manual

1993–90

00400–BR022

6.95

Collision Repair Manual

1989–86

00400–BRM00–1E

8.95

COROLLA
Collision Repair Manual

1997–93

00400–BR038

15.00

Collision Repair Manual–Sedan

1992–87

00400–BR012

6.95

Collision Repair Manual–All Trac

1992–88

00400–BR014

4.95

Collision Repair Manual–Wagon

1992–88

00400–BR013

4.95

Collision Repair Manual–FX

1988–87

00400–BRM00–6E

4.95

Collision Repair Manual–FF/FR

1987–83

00400–36434–E

6.95

(Front Wheel Drive/Rear Wheel Drive)

PRICES SUBJECT TO CHANGE WITHOUT NOTICE

ORDERING INFORMATION ON PAGE 5

TOYOTA COLLISION REPAIR & REFINISH

PAGE 2 of 5

SERVICE PUBLICATIONS (cont’d)

COLLISION REPAIR MANUALS (cont’d)

Model

Year

Part Number

Price

CRESSIDA
Collision Repair Manual

1992–89

00400–BR016

$6.95

Collision Repair Manual–Sedan

1992–87

00400–BR012

6.95

Collision Repair Manual–Wagon

1992–88

00400–BR014

4.95

LANDCRUISER
Collision Repair Manual

1997–93

00400–BR050

15.00

MR2
Collision Repair Manual

1995–91

00400–BR025

6.95

Collision Repair Manual

1989–85

00400–36440–A

15.00

Collision Repair Manual–T–Roof

1989–87

00400–BRM00–8E

4.95

PASEO
Collision Repair Manual

1997–96

00400–BR05

15.00

Collision Repair Manual–Convertible

1997

00400–BR065

15.00

Collision Repair Manual

1995–92

00400–BR030

9.00

PREVIA
Collision Repair Manual

1997–91

00400–BR027

6.95

RAV4
Collision Repair Manual

1997–96

00400–BR045

20.00

Collision Repair Manual–5–Door

1997–96

00400–BR052

15.00

SUPRA
Collision Repair Manual

1997–93

00400–BR042

9.00

Collision Repair Manual–Sport Roof

1992–86

00400–BRM00–5E

6.95

Collision Repair Manual

1992–86

00400–BRM00–9E

4.95

SUPRA, CELICA
Collision Repair Manual

1986–82

00400–36182

6.95

TERCEL
Collision Repair Manual

1997–95

00400–BR047

20.00

Collision Repair Manual

1994–92

00400–BR029

9.00

Collision Repair Manual–Sedan

1991–86

00400–BRM00–7U

6.95

Collision Repair Manual–Coupe

1991–87

00400–BRM01–1U

4.95

Collision Repair Manual

1986–85

00400–36431–E

6.95

Collision Repair Manual–4WD

1988–83

00400–36432–E

6.95

VAN
Collision Repair Manual

1989–84

00400–BRM00–3E

6.95

4RUNNER
Collision Repair Manual

1997–96

00400–BR060

20.00

PRICES SUBJECT TO CHANGE WITHOUT NOTICE

ORDERING INFORMATION ON PAGE 5

TOYOTA COLLISION REPAIR & REFINISH

PAGE 3 of 5

SERVICE PUBLICATIONS (cont’d)

COLLISION REPAIR SUPPORT MATERIALS

These manuals focus on the fundamental skills necessary to develop a qualified body or
paint technician.

Each title is useful for:

Quick reference guidelines

Fundamental repair information

Basic diagnostic and damage assessment

Name

Part Number

Price

FUNDAMENTAL BODY
REPAIR PROCEDURES

Fundamental Manual

00400–BRM00–2E

$14.95

FUNDAMENTAL PAINTING
PROCEDURES

Fundamental Manual

00400–BR024

19.00

COLLISION REPAIR TRAINING COURSE PACKAGES

Each of these course packages are used exclusively at all Toyota Collision Repair and
Refinish Training Centers and are available as self–study training packages for technicians
performing collision repair and refinish operations.

Each training package includes a technician reference guide, videotape and learning aid.

Topics covered include:

Cutting and welding procedures

Body panel replacement

Preparation procedures for refinish

Color evaluation

Name

Part Number

Price

Toyota Paint
Finish Repair (PFR)

00400–10000

$54.95

Toyota Color Matching
For Painters (CMFP)

00415–10002

54.95

Toyota Advanced
Painting Techniques (APT)

00415–10004

54.95

Toyota Non–Structural
Body Repair Techniques (NBRT)

00415–10001

54.95

Toyota Structural
Body Repair Techniques (SBRT)

00415–10003

54.95

PRICES SUBJECT TO CHANGE WITHOUT NOTICE

ORDERING INFORMATION ON PAGE 5

TOYOTA COLLISION REPAIR & REFINISH

PAGE 4 of 5

SERVICE PUBLICATIONS (cont’d)

COLLISION REPAIR INFORMATION BULLETINS

Collision Repair Information Bulletins (CRIBS) provide Toyota body and paint technicians
with the latest developments in collision repair and refinish. Information is divided among
the following topics:

General information

Interior

Structural repair

Electrical

Welding

Alignment

Refinish

Tools and equipment

Exterior

Name

Part Number

Price

Collision Repair Information Binder
includes Bulletins #1–41

00408–03000–01

$20.00

CRIB Bulletin #49

00408–03000–49

1.00

CRIB Bulletins #51–57

00408–03000–51–57

10.00

CRIB Bulletins #58–61

00408–03000–58–61

5.00

CRIB Bulletins #62–65

00408–03000–62–65

5.00

CRIB Bulletins #66–67

00408–03000–66–67

5.00

CRIB Bulletins #68–69

00408–03000–68–69

1.18

CRIB Bulletin #70

00408–03000–70

2.00

CRIB Bulletin #71

00408–03000–71

2.24

CRIB Bulletin #72

00408–03000–72

1.62

BODY DIMENSIONS GUIDE

The Toyota Body Dimension Guide provides data necessary to assess the extent of
collision damage by using vehicle–specific dimension charts and measurement
specifications. The dimension guide provides specifications for the following areas:

engine compartment

suspension crossmember

door and compartment openings

frame alignment

underbody

cab alignment

1980–1997 Body Dimension Guide

00117–00540–97

$3.50

TOYOTA COLLISION REPAIR & REFINISH

PAGE 5 of 5

SERVICE PUBLICATIONS (cont’d)

NO8908

(Three-Dimensional Distance)

Imaginary
Standard
Line

mm (in.)

Hole dia.

10 (0.39)

18 (0.71)

14 (0.55)nut
10 (0.39)nut

18 (0.71)

10 (0.39)nut

12 (0. 47)nut

Name

Front floor reinforcement standard hole

Rear floor side member standard hole

Rear suspension member installation nut
Suspension member bracket installation nut-front, outer

Rear floor side member rear standard hole

Tank band installation nut

Transport hook installation nut

Symbol

L, l

M, m

N, n

P, p

Q, q

Hole dia.

7 (0.28)

9 (0.35)

18 (0.71)
13 (0.51)

14 (0.55) nut

18 (0.71)

10 (0.39) nut
10(0.39) nut

Name

Font side member standard hole

Font crossmember working hole

Font side member standard hole
Font suspension crossmember installation hole

Front suspension crossmember installation nut
Front side member standard hole

Engine rear mounting member installation nut-front
Propeller shaft center support bearing installation nut

Symbol

A, a

B, b

D, d

F, f

H, h

I, i

J, j

K, k

UNDER

BODY

DIMENSIONS

DI-8

NOTICE: T

rue up the mounting section of

the front airbag sensor very carefully and

accurately so that the sensor can be

mounted at the correct angle.

NO8948

Wheel base

2,550 (100.39)

Imaginary
Standard
Line

mm (in.)

wo-Dimensional

Distance)

Hole dia.

10 (0.39)nut

10 (0.39)

18 (0.71)

14 (0.55)nut

9 (0.35)

10 (0.39)nut

18 (0.71)

10 (0.39)nut

12 (0.47)nut

Name

Propeller shaft center support bearing installation nut
Front floor reinforcement standard bole
Rear floor side member standard hole

Rear suspension member installation nut

Rear spring support hole-outer

Suspension member bracket installation nut-front, outer

Rear floor side member rear standard hole

Tank band installation nut

Transport hook installation nut

Symbol

K, k

L, l

M, m

N, n

O, o

P, p

Q, q

Hole dia.

7 (0.28)
9 (0.35)
9 (0.35)

18 (0.71)

8 (0.31) nut

13 (0.51)

14 (0.55) nut

18 (0.71)

10 (0.39) nut

Name

Front side member standard hole
Front crossmember working hole
Front airbag sensor installation hole

Front side member standard bole

Front airbag sensor installation nut

Front suspension crossmember installation hole

Front spring support hole-outer

Front suspension crossmember installation nut

Front side member standard hole
Engine rear mounting member installation nut-front

Symbol

A, a
B, b
C, c

D, d

E, e

F, f

G, g

H, h

I, i

J, j

UNDER

BODY (Cont’d)

BODY

DIMENSIONS

DI-9

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

URETHANE ADHESIVE SEALANT FOR

PAGE 1 of 3

FIXED GLASS INSTALLATION

SECTION:

STRUCTURAL REPAIR

BULLETIN #31

MODELS:

ALL

DATE:

NOVEMBER 1988

In order to comply with FMVSS 212 – Windshield Retention and FMVSS 216 – Roof Crush
Resistance, the factory uses a urethane adhesive sealant with bonded strength of not less
than 40 kilograms per square centimeter or 569 pounds per square inch for certain bonded
windshields and rear windows on Toyota vehicles.

A Urethane adhesive sealant of at least equivalent strength must be used to maintain
these retention and roof crush standards when windshield glass replacements are
performed by either the dealer or an outside glass shop.

Since the adhesive kits listed in Toyota Repair Manuals are not available in the U.S.A., a
listing of some locally available equivalent materials is provided below. Be sure to follow
the sealant manufacturer’s instructions for best results.

CVS Urethane Auto Glass Sealer by American Sure Seal
Bonding strength = 600 pounds per square in. (approximate)

Super Fast Urethane by 3M
Bonding strength = 1000 pounds per square in. (approximate)

Unrest 212 by Kent Industries
Bonding strength = 600 pounds per square in. (approximate)

Urethane E Auto Glass Sealer by Protective Treatment Inc.
Bonding strength = 600 pounds per square in. (approximate)

For more detailed application information, see the attached “Urethane Adhesive Sealant
Application for Toyota Models”.

Rear quarter windows on some models are bonded, however, the adhesive for these
windows requires less bonding strength and therefore, use of Butyl sealer may be sufficient
for these windows.

This bulletin is for information and clarification purposes only. Existing Warranty policy and
Flat Rate information have not been changed. Toyota is not responsible for problems that
occur from usage of improper sealants or procedures which fail to meet Toyota
specifications. PLEASE CONSULT THE APPROPRIATE TOYOTA SERVICE MANUAL
FOR THE PROPER REPAIR PROCEDURES.

NOTE: PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER
MANAGER

URETHANE ADHESIVE SEALANT FOR FIXED

PAGE 2 of 3

GLASS INSTALLATION (cont’d)

URETHANE ADHESIVE SEALANT APPLICATION FOR TOYOTA MODELS

MODEL

BODY

WINDSHIELD

REAR WINDOW

QUARTER

WINDOW

TERCEL

AL/EL
8608 to date EL

2–Dr Sdn
4–Dr Sdn
5–Dr Sdn

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

8308 to 8802 AL

5–Dr Wgn

Urethane

Bonded

Conventional

Weatherstrip

Conventional

Weatherstrip

8208 to 8607 AL

3–Dr L/B

Urethane

Bonded

Conventional

Weatherstrip

Conventional

Weatherstrip

COROLLA

2–Dr S/C

4–Dr Sdn

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

FWD AE
8708 to date

All–Trac Wgn

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

4–Dr Wgn

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

FWD AE

4–Dr Sdn

Urethane

Bonded

Conventional

Weatherstrip

Conventional

Weatherstrip

FWD AE
8409 to 8707

5–Dr L/B

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

FX Models
8608 to 8807

3–Dr L/B

Urethane

Bonded

Conventional

Weatherstrip

Conventional

Weatherstrip

RWD AE
8409 to 8707

2–Dr S/C

2–Dr L/B

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

MR2

AW 8501 to date

2–Seater

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

CELICA

ST 8509 to date

2–Dr S/C

2–Dr L/B

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

SUPRA

MA70 8601 to date

2–Dr L/B

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

URETHANE ADHESIVE SEALANT FOR FIXED

PAGE 3 of 3

GLASS INSTALLATION (cont’d)

URETHANE ADHESIVE SEALANT APPLICATION FOR TOYOTA MODELS (cont’d)

MODEL

BODY

WINDSHIELD

REAR WINDOW

QUARTER

WINDOW

CAMRY

SV/VV

4–Dr Sdn

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

SV/VV
8609 to date

5–Dr Wgn

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

SV/CV
8409 to 8608

4–Dr Sdn

5–Dr L/B

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

CRESSIDA

MX 8808 to date

4–Dr Sdn

Urethane

Bonded

Conventional

Weatherstrip

Urethane

Bonded

8404 to 8807

4–Dr Sdn

Urethane

Bonded

Urethane

Bonded

Butyl

Bonded

8404 to 8807

5–Dr Wgn

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

VAN

YR 8309 to date

Passenger/

Cargo

Urethane

Bonded

Conventional

Weatherstrip

Conventional

Weatherstrip

LAND CRUISER

4–Dr Wgn

Conventional

Weatherstrip

Conventional

Weatherstrip

Conventional

Weatherstrip

TRUCK

RN/LN
8808 to date

4 x 2
4 x 4

Refer to

Service
Manual

Conventional

Weatherstrip

Conventional

Weatherstrip

TRUCK

RN/LN
8309 to 8807

4 x 2
4 x 4

Refer to

Service
Manual

Conventional

Weatherstrip

Conventional

Weatherstrip

4RUNNER

8408 to date

All

Urethane

Bonded

Conventional

Weatherstrip

Butyl

Bonded

The following urethane adhesive kits described in Toyota Repair Manuals are not available
in the U.S.A.

Adhesive Kits in Toyota Repair Manuals

P/N

08850–00070 32 to 59 degrees F (0 to 15 degrees C)

08850–00080 59 to 95 degrees F (15 to 35 degrees C)

08850–00090 95 to 113 degrees F (35 to 45 degrees C)

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

PAINT VENDOR TECHNICAL

PAGE 1 of 1

SERVICE SUPPORT

SECTION:

GENERAL INFORMATION BULLETIN #77

MODELS:

ALL

DATE:

MARCH 1997

For your reference, we are providing the following technical service telephone numbers
and support features offered by your respective paint supplier. Please contact the suppliers
directly to receive important technical and refinish product information.

BASF

SHERWIN–WILLIAMS

800–825–3000

800–798–5872

(For Martin Senour 800–526–6704)

8:00 AM to 8:00 PM EST

8:30 AM to 5:00 PM EST

technical information

technical applications assistance

product information

color match assistance

color information

technical training, locations/dates

DUPONT

SIKKENS

800–222–5225

800–521–9222

8:00 AM to 4:30 PM EST

8:00 AM to 6:00 PM EST

technical service

technical support

paint system selection

color information

training information

ICI AUTOCOLOR

SPIES–HECKER

800–647–6050

800–447–7437

8:00 AM to 5:30 PM EST

8:00 AM to 6:00 PM EST

technical product/process information

technical information

color information

PPG

STANDOX

technical service (216) 572–6111

800–551–9296

8:00 AM to 6:00 PM EST

8:00 AM to 7:00 PM EST

color library (216) 572–6100

product technical issues – x3108

8:00 AM to 6:00 PM EST

color issues –x3109 or 3110

training info./schedules

training issues – x3139 or 3118

(800) 450–2654 24–hour service

Information and specific technical procedures for the repair and refinish of Toyota vehicles
may be obtained by attending a Toyota Collision Repair and Refinish Training course.

Toyota courses are designed to enhance the skills of collision repair technicians and
provide detailed information in order to simplify and improve the quality of each repair.
Courses are taught at each Toyota Collision Repair and Refinish Training Center.

For additional information about Toyota Collision Repair and Refinish Training courses and
a course schedule, please contact your local Toyota regional office.

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

WELDING HIGH STRENGTH

PAGE 1 of 5

STEEL (H.S.S.)

SECTION:

WELDING

BULLETIN #27

MODELS:

ALL TOYOTA MODELS

DATE:

JULY 1988

In today’s body shop environment high strength steel (H.S.S.) body parts are frequently
welded during collision damage repairs. Typical uses for H.S.S. are the front cross
member, front body outer pillar, floor side member and door side impact protection beam.
Because H.S.S. is used in these areas of potential high stress, repairs must be done
properly to maintain the structural integrity of the vehicle.

Two types of H.S.S. are used. Solution hardened H.S.S. is used for door panels, hood
outer panel, etc., while precipitation hardened H.S.S. is used for door impact beams and
bumper reinforcements. It is not necessary to distinguish solid solution hardened steel from
ordinary steels for repair purposes.

The location of H.S.S. parts can be found in the Toyota Repair Manual for Collision
Damage under the Body Panel Construction section. A sample chart from the 1987 Camry
Collision Repair Manual is on page 3 of this bulletin. A list of available Toyota Collision
Repair manuals is on page 4.

REPAIR GUIDELINES

H.S.S. and ordinary steel parts in Toyota vehicles are welded using the same methods.
The following precautions apply:

Use either spot welding or MIG/MAG (shield gas) welding. MIG/MAG (shield
gas) welding should only be done by an experienced body shop person.

Only braze body components previously brazed at the factory and as indicated in
the Toyota Repair Manual for Collision Damage.

Do not use an oxy–acetylene torch for fusion welding auto bodies. The large
heat affected zone may destroy galvanized coatings and cause excessive panel
distortions. In addition, an oxy–acetylene torch will reduce the strength and
increase the brittleness of H.S.S.

WELDING HIGH STRENGTH STEEL (cont’d)

PAGE 2 of 5

REFERENCE MATERIALS

The following manuals should be readily available in the body shop:

Toyota Fundamental Body Repair Procedures Manual

Complete set of Toyota Repair Manuals for Collision Damage

TOOLS

Proper tools are mandatory for H.S.S. repair. Tools include:

MIG/MAG welder

Spot welder

H.S.S. spot weld cutter that will cut 8mm and 10mm holes

Air saw

Plasma cutter

Air power chisel with panel cutter

Hole punch

Head protector

Dust mask

Face protector

Vise grip pliers

Weld through primer (see page 5 of this bulletin)

Ear plugs

Car cover for glass and interior

WELDS

Four types of welding are required in the repair of Toyota vehicles:

Spot

Plug

Continuous

Braze

Technicians doing repair work must be proficient in doing all four types of welding since all
four are used in various locations throughout the vehicle. The Toyota Repair Manuals for
Collision Damage show the location and type of welds that must be used. The correct
number and type of welds must be used to ensure structural integrity.

PROCEDURE

The complete in–depth procedure for welding H.S.S. and ordinary steel can be found in the
Toyota Fundamental Body Repair Procedures manual for the applicable vehicle. The basic
procedure requires:

1. Removal of auxiliary parts

2. Removal of damaged parts

3. Prepare new parts

4. Position new parts

5. Welding

6. Finishing of welded areas.

WELDING HIGH STRENGTH STEEL (cont’d)

PAGE 3 of 5

BODY PANEL CONSTRUCTION — High Strength Steel (H.S.S.) Parts

WELDING HIGH STRENGTH STEEL (cont’d)

PAGE 4 of 5

TOYOTA SERVICE PUBLICATIONS

PART NUMBER

DESCRIPTION

3643–8E

Fundamental Painting Procedures

BRM00–2E

Fundamental Collision Repair

3643–1E

Tercel 2WD

3643–2E

Tercel 4WD

3643–4E

Corolla 83–87

36182

Celica/Supra 82–86

BRM00–1E

Celica 86–88

BRM00–5E

Supra 86–88

3643–3E

Camry 83–86

36118

Cressida 81–84

3644–1E

Cressida 85–88

3644–2E

Cressida Wgn. 85–88

3644–oA

MR2 85–88

BRM00–3E

Van 84–87

BRM01–1U

Tercel Coupe 87–88

BRM01–0U

Camry 87

BRM00–7U

Tercel Sedan 87–88

BR012

Corolla 88

BRM00–6E

FX/FX 16 87–88

BRM00–9E

Supra Sport Roof 86–88

BRM00–8E

MR2 T–Roof 85–88

You may order these on your TDN through the non–parts ordering system.

WELDING HIGH STRENGTH STEEL (cont’d)

PAGE 5 of 5

WELD–THROUGH PRIMER SUPPLIERS *

HTP “Cold Galvanizing Compound”
Part No. 12022
HTP America, Inc.
261 Woodwork Lane
Palatine, IL 60067

TTE “Dan–Prime”
Transnational Technology Enterprises, Inc.
3541 Old Conejo Road, #107
Newbury Park, CA 91320

Anchor Brand “Spray–Galv”
NASCO
Welding Equipment and Safety Supplies
Chicago, IL

3M “Weld–Thru Coating”
Part No. 051131–05913
3M Automotive Trades Division
St. Paul, MN

Kent “Spotweld Primer”
Part No. 50190
Kent Industries
4500 Euclid Ave.
Cleveland, OH 44103

* There may be other sources for this material that are not listed here.

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

1997 PAINT AND REFINISH

PAGE 1 of 4

FORMULA CODES

SECTION:

REFINISH

BULLETIN #74

MODELS:

ALL

DATE:

JANUARY 1997

Attached for your reference is a list of all 1997 Toyota paint codes and the refinish paint
codes for the following refinish paint manufacturers:

BASF, DuPont, PPG, Sherwin–Williams, Sikkens, Spies–Hecker, and ICI
Autocolor.

NOTE: The vehicle paint code is on the certification label which can be located on the
driver’s side door jamb or the lower section of the “B” pillar.

NOTE: Please contact your local paint representative for the actual paint mixing formulas
or if you need help in color matching.

1997 TOYOTA PAINT CODES AND COLOR NAMES

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

040

Super White

Toy040

W8430

90288

35000

Toy040

16170

KK47

041

White

Toy041

L8416

90274

34792

Toy041

17618

KJ64

045

Super White

Toy045

H8931

90547

38712

Toy045

16004

NP65

051

Diamond

White Pearl

Toy051

L9246

L9247

90822

90826

42872

42873

Toy051

98125

16329

PF76B

TD86G

056

Natural

White

Toy056

F1858

91452

52893

Toy056

15217

BAB5

1A0

Platinum

Metallic

Toy1A0

N9923

4896

49700

Toy1A0

70809

6ED5B

1A1

Anthracite

Metallic

Toy1A1

L9991

4897

48977

Toy1A1

80164

5TX2B

1A2

Topaz

Metallic

Toy1A2

F0016

4898

49701

Toy1A2

70855

6ED9B

1A5

Desert Dune

Pearl

Toy1A5

F1458

36090

52139

Toy1A5

72759

8NH3B

1A6

Moonglow

Pearl

Toy1A6

F1459

36091

52140

Toy1A6

72760

8NH4B

1B1

Champagne

Pearl

Toy1B1

F2186

5252

53074

Toy1B1

20699

FLT9B

1B2

Antique Sage

Pearl

Toy1B2

F2201

5324

54757

Toy1B2

73622

HRE5B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 2 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

183

Blue Slate

Metallic

Toy183

K9318

35139

44338

Toy183

98625

2698B

191

Graystone

Pearl

Toy191

F1051

5046

51142

Toy191

91326

2N7JB

193

Opal Beige

Pearl

Toy193

L9881

4899

49669

Toy193

70430

4YV6B

196

Pewter Pearl

Toy196

H9878

4742

47605

Toy196

70401

4SS6B

199

Alpine Silver

Metallic

Toy199

L9990

4900

48976

Toy199

70706

5TX1B

202

Black

Toy202

F0220

9300

1738SW

8803MS

Toy202

73935

TH21B

204

Black Metal-

lic

Toy204

H8645

9624

35533

Toy204

96020

A237B

205

Satin Black

Metallic

Toy205

L9024

9756

40888

Toy205

97765

B941B

3E5

Super Red

Toy3E5

W8431

72717

35001

Toy3E5

38916

KK41

3E6

Bright Red

Toy3E6

W8432

72718

35002

Toy3E6

38240

KK42

3H4

Medium Red

Pearl

Toy3H4

N8833

73074

38386

Toy3H4

97117

PA49B

3H7

Cardinal Red

Toy3H7

L9026

73279

40890

Toy3H7

38805

WJ91

3J7

Garnet Red

Pearl

Toy3J7

L9346

4402

4403

44407

44408

Toy3J7

98626

38992

PH375B

3J8

Prussian Red

Pearl

Toy3J8

W9463

4596

46590

Toy3J8

99827

PT73B

3K4

Sunfire Red

Pearl

Toy3K4

W9546

4511

46144

Toy3K4

99722

PM54B

3L2

Renaissance

Red

Toy3L2

L9992

4902

48978

Toy3L2

30491

5TX3B

3L3

Ruby Red

Pearl

Toy3L3

F0294

5042

51162

Toy3L3

30914

6KD3B

3L5

Radiant Red

Toy3L5

F2688

5287

54291

Toy3L5

33476

JNK8

3L9

Coral Rose

Pearl

Toy3L9

F2727

5335

54763

Toy3L9

33609

HRF2B

4K9

Sandstone

Beige Metallic

Toy4K9

N9216

26846

43482

Toy4K9

98224

2575B

4M4

Sierra Beige

Metallic

Toy4M4

H9879

4743

47606

Toy4M4

20157

4SS7B

4M9

Cashmere

Beige Metallic

Toy4M9

N9924

4903

49702

Toy4M9

20261

6ED6B

4N5

Vintage Rose

Metallic

Toy4N5

F2716

5339

54862

Toy4N5

61953

HYV5B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 3 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

6M1

Dark Emer-

ald Green

Pearl

Toy6M1

W9542

4595

46589

Toy6M1

99746

PM72B

6M3

Silver Spruce

Metallic

Toy6M3

W9514

4474

45931

Toy6M3

99679

D381B

6N5

Sequoia

Green

Metallic

Toy6N5

F0698

5195

53003

Toy6N5

61270

7DK1B

6N7

Sierra Green

Metallic

Toy6N7

F1036

5047

51163

Toy6N7

61391

7PP1B

6P2

Classic

Green Pearl

Toy6P2

F1850

5173

52889

Toy6P2

61953

BAA7B

6P3

Deep Jewel

Green Pearl

Toy6P3

F1805

5166

52887

Toy6P3

61928

ARD3B

6P5

Bright Ivy

Pearl

Toy6P5

F2266

5326

54764

Toy6P5

64196

HDJ7B

6P6

Meadow

Green Pearl

Toy6P6

F2718

N/A

54483

Toy6P6

64101

HDJ3B

6P9

Glacier Green

Metallic

Toy6P9

F2721

5333

54760

Toy6P9

64198

HRE8B

748

Ocean Mist

Metallic

Toy748

L9679

4636

53004

Toy748

91343

PT69B

751

Evergreen

Pearl

Toy751

H9881

4746

47857

Toy751

60290

4SS9B

754

Paradise

Blue Metallic

Toy754

F0893

5043

51166

Toy754

53753

8VR3B

756

Light Tur-

quoise Pearl

Toy756

F1856

5171

52891

Toy756

61954

BAB1B

8K0

Night Shad-

ow Pearl

Toy8K0

N9925

4910

49707

Toy8K0

50887

6ED7B

8K1

Orchid Blue

Pearl

Toy8K1

F0605

5044

51167

Toy8K1

53510

7DJ8B

8K4

Confetti Blue

Metallic

Toy8K4

F0699

5196

53005

Toy8K4

53552

7DK2B

8K6

Cobalt Blue

Metallic

Toy8K6

F0892

5045

51168

Toy8K6

53754

8VR2B

8K8

Brilliant Blue

Pearl

Toy8K8

F1800

5161

52884

Toy8K8

54221

ARC7B

8K9

Bright Iris

Pearl

Toy8K9

F1038

5051

51169

Toy8K9

53728

7PP9B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 4 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

8L3

Blue Velvet

Pearl

Toy8L3

F2239

5328

54032

Toy8L3

54676

FRC7B

8L5

Royal Sap-

phire Pearl

Toy8L5

F2728

5329

54485

Toy8L5

55068

HDJ4B

8L6

Azure Blue

Pearl

Toy8L6

F2058

5205

53071

Toy8L6

54561

ETB8B

8L7

Stellar Blue

Pearl

Toy8L7

F2059

5206

53072

Toy8L7

54562

ETB9B

925

Purple Storm

Metallic

Toy925

L9681

5197

53006

Toy925

91614

PT74B

926

Lavender

Steel Metallic

Toy926

F2060

5207

53073

Toy926

40582

ETC1B

927

Shadow

Plum Pearl

Toy927

F0899

5053

51170

Toy927

80374

7PR2B

930

Blue Dusk

Pearl

Toy930

F2723

5330

54758

Toy930

40713

HRE6B

931

Frosted Iris

Metallic

Toy931

F2724

5331

54759

Toy931

40714

HRE7B

932

Misty Plum

Metallic

Toy932

F2267

5284

53981

Toy932

40663

GNL8B

933

Fiesta Blue

Metallic

Toy933

F2695

5291

54297

Toy933

40664

GNM3B

936

Deep Violet

Pearl

Toy936

F2726

5334

54761

Toy936

40715

HRE9B

TWO TONE COMBINATIONS

2AB

1A5 Desert
Dune Pearl

1A6 Moonglow

Pearl

Toy1A5

Toy1A6

F1458

F1459

36090

36091

52139

52140

Toy1A5

Toy1A6

72759

72760

8NH3B

8NH4B

2AC

6M1 Dark Emer-

ald Pearl

1A6 Moonglow

Pearl

Toy6M1

Toy1A6

W9542

F1459

4595

36091

46589

52140

Toy6M1

Toy1A6

99746

72760

PM72B

8NH4B

2BV

6N7 Sierra

Green Metallic

6P0 Gray/Green

Metallic

Toy6N7

Toy6P0

F1036

F1799

5047

5325

51163

52883

Toy6N7

Toy6P0

61361

61753

7PP7B

ARC5B

28X

196 Pewter

Pearl

202 Black

Toy196

Toy202

H9878

F0220

4742

9300

47605

1738SW

8803MS

Toy196

Toy202

70401

79335

4226B

TH21B

NOTE:

Standox uses the Toyota color code to identify the color.
Example: Toyota color code 056 = Standox 056

For additional information about color matching Toyota vehicles, refer to the repainting
section of the Toyota Fundamental Painting procedure manual (part # 00400–BR024) or
contact your regional office to obtain information about Toyota Collision Repair and
Refinish Training Programs.

FOR THE TOYOTA DEALER

OLLISION

EPAIR

NFORMATION

TITLE:

1997 PAINT AND REFINISH

PAGE 1 of 4

FORMULA CODES

SECTION:

REFINISH

BULLETIN #74

MODELS:

ALL

DATE:

JANUARY 1997

Attached for your reference is a list of all 1997 Toyota paint codes and the refinish paint
codes for the following refinish paint manufacturers:

BASF, DuPont, PPG, Sherwin–Williams, Sikkens, Spies–Hecker, and ICI
Autocolor.

NOTE: The vehicle paint code is on the certification label which can be located on the
driver’s side door jamb or the lower section of the “B” pillar.

NOTE: Please contact your local paint representative for the actual paint mixing formulas
or if you need help in color matching.

1997 TOYOTA PAINT CODES AND COLOR NAMES

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

040

Super White

Toy040

W8430

90288

35000

Toy040

16170

KK47

041

White

Toy041

L8416

90274

34792

Toy041

17618

KJ64

045

Super White

Toy045

H8931

90547

38712

Toy045

16004

NP65

051

Diamond

White Pearl

Toy051

L9246

L9247

90822

90826

42872

42873

Toy051

98125

16329

PF76B

TD86G

056

Natural

White

Toy056

F1858

91452

52893

Toy056

15217

BAB5

1A0

Platinum

Metallic

Toy1A0

N9923

4896

49700

Toy1A0

70809

6ED5B

1A1

Anthracite

Metallic

Toy1A1

L9991

4897

48977

Toy1A1

80164

5TX2B

1A2

Topaz

Metallic

Toy1A2

F0016

4898

49701

Toy1A2

70855

6ED9B

1A5

Desert Dune

Pearl

Toy1A5

F1458

36090

52139

Toy1A5

72759

8NH3B

1A6

Moonglow

Pearl

Toy1A6

F1459

36091

52140

Toy1A6

72760

8NH4B

1B1

Champagne

Pearl

Toy1B1

F2186

5252

53074

Toy1B1

20699

FLT9B

1B2

Antique Sage

Pearl

Toy1B2

F2201

5324

54757

Toy1B2

73622

HRE5B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 2 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

183

Blue Slate

Metallic

Toy183

K9318

35139

44338

Toy183

98625

2698B

191

Graystone

Pearl

Toy191

F1051

5046

51142

Toy191

91326

2N7JB

193

Opal Beige

Pearl

Toy193

L9881

4899

49669

Toy193

70430

4YV6B

196

Pewter Pearl

Toy196

H9878

4742

47605

Toy196

70401

4SS6B

199

Alpine Silver

Metallic

Toy199

L9990

4900

48976

Toy199

70706

5TX1B

202

Black

Toy202

F0220

9300

1738SW

8803MS

Toy202

73935

TH21B

204

Black Metal-

lic

Toy204

H8645

9624

35533

Toy204

96020

A237B

205

Satin Black

Metallic

Toy205

L9024

9756

40888

Toy205

97765

B941B

3E5

Super Red

Toy3E5

W8431

72717

35001

Toy3E5

38916

KK41

3E6

Bright Red

Toy3E6

W8432

72718

35002

Toy3E6

38240

KK42

3H4

Medium Red

Pearl

Toy3H4

N8833

73074

38386

Toy3H4

97117

PA49B

3H7

Cardinal Red

Toy3H7

L9026

73279

40890

Toy3H7

38805

WJ91

3J7

Garnet Red

Pearl

Toy3J7

L9346

4402

4403

44407

44408

Toy3J7

98626

38992

PH375B

3J8

Prussian Red

Pearl

Toy3J8

W9463

4596

46590

Toy3J8

99827

PT73B

3K4

Sunfire Red

Pearl

Toy3K4

W9546

4511

46144

Toy3K4

99722

PM54B

3L2

Renaissance

Red

Toy3L2

L9992

4902

48978

Toy3L2

30491

5TX3B

3L3

Ruby Red

Pearl

Toy3L3

F0294

5042

51162

Toy3L3

30914

6KD3B

3L5

Radiant Red

Toy3L5

F2688

5287

54291

Toy3L5

33476

JNK8

3L9

Coral Rose

Pearl

Toy3L9

F2727

5335

54763

Toy3L9

33609

HRF2B

4K9

Sandstone

Beige Metallic

Toy4K9

N9216

26846

43482

Toy4K9

98224

2575B

4M4

Sierra Beige

Metallic

Toy4M4

H9879

4743

47606

Toy4M4

20157

4SS7B

4M9

Cashmere

Beige Metallic

Toy4M9

N9924

4903

49702

Toy4M9

20261

6ED6B

4N5

Vintage Rose

Metallic

Toy4N5

F2716

5339

54862

Toy4N5

61953

HYV5B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 3 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

6M1

Dark Emer-

ald Green

Pearl

Toy6M1

W9542

4595

46589

Toy6M1

99746

PM72B

6M3

Silver Spruce

Metallic

Toy6M3

W9514

4474

45931

Toy6M3

99679

D381B

6N5

Sequoia

Green

Metallic

Toy6N5

F0698

5195

53003

Toy6N5

61270

7DK1B

6N7

Sierra Green

Metallic

Toy6N7

F1036

5047

51163

Toy6N7

61391

7PP1B

6P2

Classic

Green Pearl

Toy6P2

F1850

5173

52889

Toy6P2

61953

BAA7B

6P3

Deep Jewel

Green Pearl

Toy6P3

F1805

5166

52887

Toy6P3

61928

ARD3B

6P5

Bright Ivy

Pearl

Toy6P5

F2266

5326

54764

Toy6P5

64196

HDJ7B

6P6

Meadow

Green Pearl

Toy6P6

F2718

N/A

54483

Toy6P6

64101

HDJ3B

6P9

Glacier Green

Metallic

Toy6P9

F2721

5333

54760

Toy6P9

64198

HRE8B

748

Ocean Mist

Metallic

Toy748

L9679

4636

53004

Toy748

91343

PT69B

751

Evergreen

Pearl

Toy751

H9881

4746

47857

Toy751

60290

4SS9B

754

Paradise

Blue Metallic

Toy754

F0893

5043

51166

Toy754

53753

8VR3B

756

Light Tur-

quoise Pearl

Toy756

F1856

5171

52891

Toy756

61954

BAB1B

8K0

Night Shad-

ow Pearl

Toy8K0

N9925

4910

49707

Toy8K0

50887

6ED7B

8K1

Orchid Blue

Pearl

Toy8K1

F0605

5044

51167

Toy8K1

53510

7DJ8B

8K4

Confetti Blue

Metallic

Toy8K4

F0699

5196

53005

Toy8K4

53552

7DK2B

8K6

Cobalt Blue

Metallic

Toy8K6

F0892

5045

51168

Toy8K6

53754

8VR2B

8K8

Brilliant Blue

Pearl

Toy8K8

F1800

5161

52884

Toy8K8

54221

ARC7B

8K9

Bright Iris

Pearl

Toy8K9

F1038

5051

51169

Toy8K9

53728

7PP9B

1997 PAINT AND REFINISH FORMULA CODES (cont’d)

PAGE 4 of 4

1997 TOYOTA PAINT CODES AND COLOR NAMES (cont’d)

COLOR

CODE

COLOR

NAME

BASF

DUPONT

PPG

SHERWIN–

WILLIAMS

SIKKENS

SPIES–

HECKER

ICI AUTO

COLOR

8L3

Blue Velvet

Pearl

Toy8L3

F2239

5328

54032

Toy8L3

54676

FRC7B

8L5

Royal Sap-

phire Pearl

Toy8L5

F2728

5329

54485

Toy8L5

55068

HDJ4B

8L6

Azure Blue

Pearl

Toy8L6

F2058

5205

53071

Toy8L6

54561

ETB8B

8L7

Stellar Blue

Pearl

Toy8L7

F2059

5206

53072

Toy8L7

54562

ETB9B

925

Purple Storm

Metallic

Toy925

L9681

5197

53006

Toy925

91614

PT74B

926

Lavender

Steel Metallic

Toy926

F2060

5207

53073

Toy926

40582

ETC1B

927

Shadow

Plum Pearl

Toy927

F0899

5053

51170

Toy927

80374

7PR2B

930

Blue Dusk

Pearl

Toy930

F2723

5330

54758

Toy930

40713

HRE6B

931

Frosted Iris

Metallic

Toy931

F2724

5331

54759

Toy931

40714

HRE7B

932

Misty Plum

Metallic

Toy932

F2267

5284

53981

Toy932

40663

GNL8B

933

Fiesta Blue

Metallic

Toy933

F2695

5291

54297

Toy933

40664

GNM3B

936

Deep Violet

Pearl

Toy936

F2726

5334

54761

Toy936

40715

HRE9B

TWO TONE COMBINATIONS

2AB

1A5 Desert
Dune Pearl

1A6 Moonglow

Pearl

Toy1A5

Toy1A6

F1458

F1459

36090

36091

52139

52140

Toy1A5

Toy1A6

72759

72760

8NH3B

8NH4B

2AC

6M1 Dark Emer-

ald Pearl

1A6 Moonglow

Pearl

Toy6M1

Toy1A6

W9542

F1459

4595

36091

46589

52140

Toy6M1

Toy1A6

99746

72760

PM72B

8NH4B

2BV

6N7 Sierra

Green Metallic

6P0 Gray/Green

Metallic

Toy6N7

Toy6P0

F1036

F1799

5047

5325

51163

52883

Toy6N7

Toy6P0

61361

61753

7PP7B

ARC5B

28X

196 Pewter

Pearl

202 Black

Toy196

Toy202

H9878

F0220

4742

9300

47605

1738SW

8803MS

Toy196

Toy202

70401

79335

4226B

TH21B

NOTE:

Standox uses the Toyota color code to identify the color.
Example: Toyota color code 056 = Standox 056

Document Outline

foreword.pdf
howtouse.pdf
symbols.pdf
handling.pdf
generalr.pdf
vehiclel.pdf
abbrevia.pdf
anticorr.pdf
bodydime.pdf
bodylowe.pdf
bodyo.pdf
bodyo0.pdf
bodyo1.pdf
bodyopen.pdf
bodyp.pdf
bodyp0.pdf
bodyp1.pdf
bodypane.pdf
cowltops.pdf
crib146.pdf
fitstand.pdf
foamedma.pdf
front.pdf
front0.pdf
front1.pdf
frontapr.pdf
frontbod.pdf
frontcro.pdf
frontdoo.pdf
frontfen.pdf
frontsid.pdf
frontsus.pdf
generali.pdf
generalinfo.pdf
handl.pdf
highstre.pdf
location.pdf
quart.pdf
quart0.pdf
quart1.pdf
quart2.pdf
quart3.pdf
quarteri.pdf
quarterp.pdf
quarterw.pdf
radiator.pdf
rearf.pdf
rearf0.pdf
rearf1.pdf
rearfloo.pdf
rearsusp.pdf
rockerou.pdf
roofp.pdf
roofpane.pdf
rustresi.pdf
scratchr.pdf
silencer.pdf
srsai0.pdf
srsai1.pdf
srsairbag0.pdf
standard.pdf
toyotaco.pdf
underbod.pdf
urethane.pdf
vendorte.pdf
weldingh.pdf
1997pain.pdf
1997paint.pdf

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